Optimal control and energy-saving analysis of common pressure rail architectures: HHEA & STEAM

In recent years several novel hydraulic architectures have been proposed with the intention of significantly increasing system efficiency. Two of these architectures, Steigerung der Energieeffizienz in der Arbeitshydraulik mobiler Arbeitsmaschinen (STEAM), and the Hybrid Hydraulic-Electric Architecture (HHEA), use a system of multiple common pressure rails (CPRs) to serve the multiple degrees-of-freedom of the machine. The key difference is that STEAM throttles hydraulic power from these rails while HHEA combines electric and hydraulic power to meet actuator demands. As a throttle-less architecture, HHEA is expected to save more energy than STEAM at the expense of added complexity. Therefore, it is useful to quantify this additional energy saving. Both systems have discrete operational choices corresponding to how the CPRs are utilized for each actuator. It is necessary to determine optimal operation for each of these architectures for analysis and fair comparison. Techniques for optimal operation of the HHEA have been developed previously from the Langrange multiplier method. Applying the same optimal control method to STEAM encountered some technical challenge leading to the optimal control algorithm not being able to satisfy certain constraints. The issue is analyzed and solved by adding noise to the optimization. Using this proposed algorithm, case studies are performed to compare the energy-saving potentials of STEAM and HHEA for two sizes of excavators and a wheel-loader performing representative duty cycles. The baseline is a standard load-sensing architecture. Results show that STEAM and HHEA can reduce energy consumption between 35-65% and 50-80% respectively.