Reducing fuel consumption of Front End Loader using regenerative hydro-static drive configuration-an experimental study

• Published in: Energy (Oxford) Vol. 162; pp. 158 - 170
• Main Authors: Bhola, M., Kumar, N., Ghoshal, S.K.
• Format: Journal Article
• Language: English
• Published: Oxford Elsevier Ltd 01-11-2018; Elsevier BV
• Subjects: Brake specific fuel consumption (bsfc); DC generators; Effects; Electric power; Electricity distribution; Energy consumption; Energy management; Energy regeneration; Fuel consumption; Fuels; Generators; Hydraulic equipment; Load; Maximum power; PID controller; Regeneration; Regenerative hydrostatic-split power transmission (RH-SPT) drive; Torque; PID controller; Fuel consumption; Regenerative hydrostatic-split power transmission (RH-SPT) drive; Energy regeneration; Energy management; Brake specific fuel consumption (bsfc)
• ISSN: 0360-5442; 1873-6785
• DOI: 10.1016/j.energy.2018.08.006

Present paper highlights the effect of under-loading the engine and the hydraulic system of a Front End Loader (FEL). In this respect, a novel idea to modify load cycle of engine is applied in the Conventional Hydrostatic-Split Power Transmission (CH-SPT) drive by incorporating additional load on the drive through the DC generator. The load on modified system, called Regenerative Hydrostatic-split power transmission (RH-SPT) drive is the loading pump unit and DC generator unit, which is used for generating equivalent duty cycle of the FEL and electrical energy generation, respectively. The excess load of the DC generator is varied through the controller depending on engine's optimal efficient torque and the load torque. This assists the engine to operate in its efficient zone during under-loading conditions. Also, a MATLAB®/Simulink model is made and validated experimentally. The validated model is analysed to compare the performances and fuel consumption of conventional HST drive, CH-SPT drive and RH-SPT drive. It is concluded that with increase in fuel consumption of the RH-SPT system by 10% and 56% of the CH-SPT and conventional drive system, the electric power regeneration through the DC generator increases by 21% and 200% of the maximum power generated in the respective system.
•Reduction in fluctuation of engine load torque and hydraulic pressure is achieved.•Best efficient zone of engine operation is identified by modifying its load cycle.•Reduction in bsfc of the RH-SPT drive during low load demand is achieved by 85%.•Reduction in bsfc of the RH-SPT drive for one complete cycle is achieved by 26%.•Storage of excess energy in battery bank is carried out for further application.