In recent decades, hybrid powertrains, especially hybrid electric power systems, have been the main research direction in the industry and have been applied to a variety of existing automotive products. It is mainly through the integration of electric motors and batteries into the power system, while maintaining vehicle performance and control, while reducing engine size, improving fuel efficiency and reducing emissions.

At the same time, the hydraulic hybrid vehicle because of its high power density, small parts which can absorb and transfer high levels of power, as well as the technology matures began to be successfully developed by. Engineers at Southwest Research Institute (SwRI) have collaborated with the US Environmental Protection Agency (EPA) to develop hydraulic hybrid technology for large vehicles. However, as with hybrid vehicles, the effective application of hydraulic mixing technology also depends on the operating conditions of the vehicle, ie how the vehicle is used.

Hybrid technology is to enhance vehicle efficiency and reduce emissions through two steps. The first is through energy recovery, especially when parking brakes to lose energy. The second is to control the engine to operate within a high efficiency range. The power system of the hydraulic hybrid vehicle includes an engine, a hydraulic drive system, and a hydraulic accumulator. Accumulators are used to store hydraulic energy just as batteries store electrical energy. During braking, the hydraulic transmission system can pump hydraulic transmission fluid from the low pressure accumulator to the high pressure accumulator and wait for the next vehicle acceleration. The accumulator stores the high level of power during braking for later use.

The amount of braking energy recovered during vehicle operation depends on the driving conditions of the vehicle. The more start-stop conditions of the vehicle, the more braking energy that can be recovered, and the more fuel efficiency. Conversely, if hybrid owners don't do as many start-stops as manufacturers do, they are likely to get lower-than-expected fuel efficiency. With this concept, 18-wheel trucks become incompetent with hybrid power. If such trucks are traveling on highways at a speed of 65 mph, most of the time, such trucks are also developed and improved over the years. It was designed to be the most efficient under such driving conditions. However, if such trucks are often run at start-stops, hybrid technology can help reduce fuel consumption by up to 50% or more.

Which vehicles can effectively use hybrid technology? Generally speaking, those vehicles that are in need of frequent start-stop operations, such as buses, delivery vehicles, garbage trucks, and vehicles that mostly require peak traffic. Hydraulic hybrid technology is particularly effective for large commercial vehicles that do not have to undertake production tasks. Because the purpose of the operation of these vehicles is often eager to pursue lower costs, hydraulic hybrid technology offers the lowest cost solution.

In the past decades of development, the focus of its efforts has been on the components and system integration in accumulators that store hydraulic energy. Although the concept of an accumulator may seem simple, it is, like most other powertrain components, a very sophisticated engineering component. Inside the accumulator, nitrogen is used to squeeze the hydraulic oil flowing in under braking conditions. At this time, the hydraulic oil and gas must be completely separated in the accumulator to ensure that the gas is not taken away by the liquid in the hydraulic system. The loss of gas, especially in high-pressure accumulators, will destroy the system's ability to store energy and reduce efficiency.

Here, an important characteristic of nitrogen is that when the hydraulic oil is squeezed into the high pressure accumulator during braking, the pressure of the gas should be doubled. As pressure becomes higher and higher, more and more liquid is squeezed into the accumulator, and energy is stored at this time. In addition to increased pressure, nitrogen is usually heated during the compression process, which usually results in energy loss in this situation. However, the integration of open plastic foam into the accumulator can significantly increase the efficiency of the accumulator. At present, the braking energy in the start-stop traffic condition can achieve an energy storage efficiency of 98% in the accumulator.

The safety of accumulators can also be ignored. SwRI has been working with manufacturers of composite pressure vessels for many years to ensure that their products meet stringent safety regulations. At the same time, relevant tests are constantly being carried out to ensure that they can withstand ultimate strength under the expected maximum internal pressure. Other assessments also ensure that the accumulator can withstand periodic pressures over the expected life cycle; the accumulator will not react with other fluids in the car, including gasoline, diesel, etc., to affect overall performance and reliability. .

Hydraulic components have been used on off-road vehicles for a long time, and their use on the road has been limited and affected for some reason. For example, many of their developments using hydraulic systems are aimed at encouraging the general public to accept less noise.

In addition to the efficiency gains achieved by the recovery and reuse of braking energy, hydraulic systems are also being used to develop accessories for these hybrid-driven automotive engines. The single engine-driven, variable displacement pump powers hydraulic motors of various displacements, driving fans, generators, air conditioning compressors, water pumps, oil pumps and power steering systems. This setting can increase the efficiency of the vehicle and satisfy the power demand of each component from the output of the engine.

For example, the radiator fan speed can be separated from the engine speed using this system, so that the fan can provide the optimum air flow at any speed required to cool the engine to its most suitable condition. At the same time, the engine water pump operates at optimal speed, providing the flow of coolant through the engine. Therefore, if the engine is operating at partial power or the outside air temperature is low, the power to drive these components and other parts of the engine can be optimized, thereby saving energy, fuel, and the like.

Engineers at the Southwest Research Institute have conducted research tests to confirm that ball pumps are ideal for this type of hydraulic circuit. It uses a very high volume, low cost ball bearing assembly. The efficiency is very high at moderate pressures of 1500 pounds per square inch (psi) or less. Under these pressures, the efficiency of such a pump is actually significantly higher than an expensive piston pump.

Hydraulic systems are also used to maintain efficiency in building equipment. The hydraulics industry has evolved from using an open, central, fixed displacement pump to using a compensating pump to pressurize and use pressurization or air flow to try to increase the efficiency of the hydraulic power system by providing the maximum pressure required for the hydraulic system flow. However, this very common application method is also problematic because of the variety of equipment and the numerous requirements for hydraulic system components. The hydraulic circuit is a hydraulic accessory drive system that maximizes drive efficiency. In the liquid cycle, it includes an engine-driven variable displacement pump and different displacement hydraulic motors.

SwRI's team recommends non-road equipment industry that should consider using multiple hydraulic pumps instead to meet the needs of various circuits in the equipment, such as excavators. A simulation study by SwRI conducted a study of a hydraulic excavator that was undergoing a loading cycle. The results showed that the use of a regenerative hydraulic circuit reduced fuel consumption by 46%.

The concept of regenerative hydraulics is not a new concept for researchers at the Southwest Research Institute. As early as 1991, it was applied for a large vehicle oil and gas suspension system and it has been patented by SwRI. SwRI envisioned the use of multiple hydraulic pumps and motors, each with separate oil-and-air suspension struts to control vehicle heave, pitch, and roll. The system was verified on a tourist bus. Four hydraulic pumps and motors are mounted on the bus and an operating information is obtained via an inline torque sensor. The manufacturer of the bus required that the passive spring rate of the vehicle with the regenerative active hydraulic system be reduced by half, and the body bumps and rollers should also be reduced by half. The goal of this project is to achieve a recovery of 75% of the drive energy for the suspension system during operation.

Because the engine speed is no longer associated with the same vehicle speed, the hybrid hydraulic power system allows the engine to operate at maximum efficiency, and the hydraulic components provide the required operational diversity. All engines have a best efficiency point when combining power and speed. Hybrid hydraulic vehicles can keep the engine running at this optimum efficiency curve under many different operating conditions.

The EPA has been assisted by SwRI and has applied these technologies and results to a variety of hydraulic commercial transport vehicles. These results obtained in simulation experiments and laboratory tests have been successfully verified in practice. Especially in the field trials of freight trucks, very substantial results have been shown, and fuel economy has improved by more than 50% in actual transportation. On the set delivery route, nearly half of the fuel consumption is saved compared to conventional vehicles that do not use hydraulic mixing technology.

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