Energy saving in working hydraulics of long booms in heavy working vehicles

• Novel component for energy saving in long boom working vehicles is proposed.
• Energy saving achieved by using an integrated electro-hydraulic energy converter
• Energy saving up to 53% in comparison with conventional fluid power system
• The total efficiency of the original system is only 29% and new system reaches 62% efficiency.

Hybridization of heavy off-highway working vehicles brings considerable energy savings in the form of a downsized internal combustion engine (ICE) by means of reduced no-load losses. In this paper, a novel energy saving opportunity in working hydraulics at the end of long booms of working vehicles is proposed. In traditional off-highway working vehicles, the working hydraulics is supplied through pipes, hoses, and valves by a hydraulic pump located near the main engine. A significant amount of energy is lost in long pipelines and hoses as well as in valve throttles. A new topology is introduced to supply the power along the long boom; the power for a hydraulic actuator is supplied by an integrated electro-hydraulic energy converter (IEHEC), which is located at the boom end. The electrical energy to the converter is supplied through electrical cables, which have negligible losses compared with a conventional fluid power supply with long pipelines. The converter transforms the electrical energy into hydraulic energy at the end of the boom, and may also recover energy for additional energy savings.