Engineering topics

Wills, Jackson

Publications and source records attributed to Wills, Jackson.

7 records

DOE OSTI2024

Comparison of Real-Time Pressure Rail Selection Algorithms for the Hybrid Hydraulic Electric Architecture: Case Study on a Track Loader

Abstract The hybrid hydraulic electric architecture (HHEA) seeks to combine the high power/torque/force density of hydraulics with the efficiency of electric machines. A set of common pressure rails is used to provide a majority of the power and this power is modulated by small electric machines to provide precise control for the operator. The HHEA has been studied in previous work using off-line dynamic programming optimization to determine energy efficient pressure rail selections, but this approach requires drive cycle information apriori. A Lagrange multiplier method has also been investigated where a set of gains (Lagrange multipliers) are optimized off-line with the idea the these gains, once determined, could be used for real-time operation. In this work, three new real-time pressure rail selection algorithms that do not require future drive cycle information are investigated; greedy, torque minimizing, and thresholding. The greedy control is found to only use 1% more energy than the globally optimal dynamic programming solution; but a model of energy loss is required.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Power Take-Off Design Study for a Small-Scale Oscillating Surge Wave Energy Converter for Powering the Blue Economy Applications

The power take-off (PTO) is an integral part of wave energy conversion, and the design process is nontrivial. Better PTOs, and better processes for selecting and designing PTO architectures for various applications, would benefit devices that assist in powering the blue economy by decreasing time and money spent on PTO design and increasing the overall energy capture performance of these devices. This paper chronicles the selection process of a PTO for a small-scale surge-type wave energy converter (WEC) for the purpose of informing future PTO selection processes. Three PTO architectures are evaluated in WEC-Sim: a hydraulic check valve PTO, a hydraulic active valving PTO, and a directly electrified PTO. Simple models of each PTO are constructed. Because a model for the small-scale device was initially unavailable, the PTOs are simulated on a large-scale device. The results are scaled down using Froude scaling and compared to results from directly simulating a small-scale model. Strong assumptions are made because this work is early in the design stages, and a coarse look at PTO options was desired. Specifically, the effectiveness of controls is investigated, along with the efficiency of energy conversion. However, energy capture is only part of the consideration; there are also logistic concerns to be considered when selecting a PTO. For example, components for large-scale WECs are so large and expensive that it may make sense to custom-build PTO components, but small-scale WECs would benefit from off-the-shelf availability because the cost of customization would be a significant portion of the total capital cost of deployment at a small scale. Submersible, off-the-shelf components are much easier to source for hydraulic PTOs. Because of highly effective controls, efficient energy conversion, and availability of marine-grade components, an active valving hydraulic PTO is selected for this small-scale surge-type WEC.

energy conversion/systems↗

DOE OSTI2023

Electric and Hydraulic Propel Torque Modulation for a Compact Track Loader With the Hybrid Hydraulic Electric Architecture (HHEA)

Abstract The Hybrid Hydraulic Electric Architecture (HHEA) has previously been proposed for off-highway vehicles to reap the efficiency and controllability benefits of electrification without needing very large electric motors. This is achieved with the use of a set of selectable common pressure rails to transmit the majority of power and small electric motors to modulate that power. Previous work has shown significant energy savings for the work circuits of a variety of machines. In this paper, the energy saving potential of HHEA for the propel circuit of a compact track loader is studied. The ports of the track hydraulic motors are selectably connected to the common pressure rails, and instead of using the electric assist motors to buck/boost pressure, as in HHEA for linear actuators, small electric assist motors are used to add/subtract torque directly. The interplay between the torque limits of the electric motors and the ability of the hydraulic motor to vary displacements is studied, along with the effect these factors have on energy saving potential. It is found that the ability to vary the displacement of the hydraulic motor allows for: more efficient electric motor operating conditions, reduced electric torque requirement, and reduced pressure rail switching events. All three of these advantages can be achieved at once using variable displacements; but trade-offs exist between these advantages (i.e. improved efficiency can be achieved at the expense of a larger electric torque requirement). Overall, the HHEA can reduce energy consumption by ∼ 36% compared to the stock machine, depending on the hydraulic motor’s ability to vary displacements, and assuming the electric motor torque is limited to 20% of that required in a direct electrification scheme.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

Power Take-Off Design Study for a Small-Scale Oscillating Surge Wave Energy Converter for Powering the Blue Economy Applications: Preprint

The power take-off (PTO) is an integral part of wave energy conversion, and the design process is nontrivial. Better PTOs, and better processes for selecting and designing PTO architectures for various applications, would benefit devices that assist in powering the blue economy by decreasing time and money spent on PTO design and increasing the overall energy capture performance of these devices. This paper chronicles the selection process of a PTO for a small-scale surge-type wave energy converter (WEC) for the purpose of informing future PTO selection processes. Three PTO architectures are evaluated in WEC-Sim: a hydraulic check valve PTO, a hydraulic active valving PTO, and a directly electrified PTO. Simple models of each PTO are constructed. Because a model for the small-scale device was initially unavailable, the PTOs are simulated on a large-scale device. The results are scaled down using Froude scaling and compared to results from directly simulating a small-scale model. Strong assumptions are made because this work is early in the design stages, and a coarse look at PTO options was desired. Specifically, the effectiveness of controls is investigated, along with the efficiency of energy conversion. However, energy capture is only part of the consideration; there are also logistic concerns to be considered when selecting a PTO. For example, components for large-scale WECs are so large and expensive that it may make sense to custom-build PTO components, but small- scale WECs would benefit from off-the-shelf availability because the cost of customization would be a significant portion of the total capital cost of deployment at a small scale. Submersible, off-the-shelf components are much easier to source for hydraulic PTOs. Because of highly effective controls, efficient energy conversion, and availability of marine-grade components, an active valving hydraulic PTO is selected for this small-scale surge-type WEC.

electric PTO↗

DOE OSTI2022

Accumulator Sizing for the Hybrid Hydraulic Electric Architecture (HHEA) Using Dynamic Programming

Abstract The Hybrid Hydraulic Electric Architecture (HHEA) is an approach to electrifying and improving that does not require very large electric machines. The majority power is provided hydraulically via a set of common pressure rails while small electric machines are used to modulate that power to meet exact demand. Each common pressure rail has an accumulator, which keeps the pressure of each rail near constant as long as the volume in the accumulator does not change much. A main pump adds or removes fluid from each accumulator as needed to reduce volume changes in the accumulators. It is the operation of this main pump which is investigated here. In previous analysis it was assumed that the size of the accumulators was large enough to account for any difference in fluid volume without significantly changing the pressure. In this paper, the required accumulator sizes are studied using a dynamic programming approach. At each time step the inlet and outlet of the main pump could be connected to any of the common pressure rails. These decisions for the main pump were optimized to minimize the required accumulator size. Case studies are conducted using drive cycles from a 22-ton excavator, a 20-ton wheel loader and a 5-ton excavator. The machines could be operated with total accumulator sizes of less than 20, 10, and 5 liters respectively. Required accumulator size was found to vary with pump flow rate, the frequency at which the pump/motor was able to change operating conditions, the tolerance level of pressure deviation and the accumulator’s polytropic index.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2021

A Power Take-Off (PTO) for Wave Energy Converters Based on the Hybrid Hydraulic-Electric Architecture (HHEA)

Wave energy is a promising renewable energy resource for coastal regions around the world, but is not yet an economically competitive source of electricity. More effective power take-off (PTO) designs would help to make wave power a feasible and clean source of energy. To do this, PTOs need to: i) enable controlled actuation, ii) convert absorbed energy into electricity efficiently, and iii) have minimal manufacturing costs. We propose a new PTO architecture that can exert arbitrary control loads on the WEC to maximize energy capture, enabling the downsizing of expensive electrical components while maintaining high efficiency. Our PTO design is based upon a hybrid hydraulic-electric architecture (HHEA). This paper compares the performance of the HHEA PTO against two other PTO designs: 1) a baseline PTO consisting of a system of rectifying check valves and accumulators, and 2) a PTO consisting of an electro-hydraulic actuator (EHA). The HHEA PTO is shown to produce much more power than the check valve PTO and the EHA PTO. Also, the required electric generator sizes for the HHEA are smaller than that of the EHA PTO. The reduced size of these components allows for a WEC which is less expensive to manufacture.

16 TIDAL AND WAVE POWER↗

DOE OSTI2021

Incorporating Valve Switching Losses Into a Static Optimal Control Algorithm for the Hybrid Hydraulic-Electric Architecture (HHEA)

The Hybrid Hydraulic-Electric Architecture (HHEA) has, in recent years, been proposed as an energy efficient alternative to conventional load-sensing architectures in mobile machines such as excavators and wheel-loaders. HHEA leverages the advantages of hydraulic power and electric power to eliminate throttling valves while also improving the energy and control performance of the system. The architecture utilizes a set of common pressure rails to provide a majority of power and and a small electric motor driven pump to modulate this power to meet the exact demand. Previous work has developed a computationally efficient Lagrange Multiplier approach for determining the optimal pressure rail selections that minimizes the energy losses in the system. The static model used considers only the energy use for each pressure rail selection but not the losses associated with the valves during the transition. This paper presents an approach to include the switching losses in the model and in the optimization procedure. To capture the switching losses, switching events between different rails and at various input and output flow rates were simulated with consideration of valve spool dynamics. A parameterized model that summarizes the losses is then obtained, allowing switching losses to be added to the previous energy analysis. The performance of the switching loss model was compared with reference data obtained from a high-fidelity simulation model. To incorporate the switching losses into optimal control algorithm, an efficient dynamic programming approach that prevents frequent switching is adopted in place of the Lagrange multiplier approach. The overall effect of switching losses on the energy consumption and optimal control decisions is presented. In general, switching losses contribute to about 9–10% of input energy.

24 POWER TRANSMISSION AND DISTRIBUTION↗