Hydraulic Hybrid Team Team: Kevin Alexander- Market and Test skid Phillip Bacon- Accumulators Tyler Degen- Accumulators Brandon Diegel- Pump/Motor Nick Hemenway- Markets and Business Luke Jackson- Valves and Control Systems Christian L’Orange- Computer Modeling and Analysis Grant Mattive- Pump/Motor Dean Simpson- Computer Modeling and Analysis Advisors: Dr. Allan Kirkpatrick, CSU Dr. Guy Babbitt, Czero Solutions, Inc. Chris Turner, Czero Solutions, Inc.

Presentation Outline Hydraulic Hybrid Overview Project Problem Statement Objectives and Constraints Market Opportunities Components and Research Courtesy of Linde Pumps Courtesy of viaggiaresempre.it

Hydraulic Hybrid Overview Utilizes regenerative braking Reduces fuel consumption and emissions High energy and power density Optimal for frequent stop and go driving of large vehicles Configurations Investigated: Series and Parallel Current development based in US and Europe

Energy Comparisons Courtesy of Parker.com Courtesy of HHV system panel

Series Hybrid Pump Low Pressure High Pressure 5000 psi Pump/Motor

Parallel Hybrid Pump/Motor Low Pressure High Pressure 5000 psi Driveshaft

Problem Statement Increase vehicle fuel economy through regenerative braking Be adaptable to multiple vehicles with only component resizing Reduce vehicle emissions Reduce vehicle maintenance costs Courtesy of ourworldtravels.com Design a hydraulic hybrid vehicle that will:

Objectives and Constraints Courtesy of ITDP

Objectives and Constraints Constraints New components cannot add more than 10% of original vehicle mass to the vehicle Payback period: less than 2 years through fuel savings and reduced maintenance cost Major components sourced from commercial manufacturers Must have an expected life span of at least 10 years

Market Decisions Population Density Refinement expectations of the vehicle Heavy reliance on bus system Find size ranges most widely used in many countries Most common chassis layout Short bus routes or stop and go drive cycles

Target Vehicle and Countries Focus on India, China, and Singapore Design will be based around 7000kg GVW  Typical of Class 4 vehicle Initial design will focus on front engine layout Simplistic control system to minimize cost

Major Components Functions as both a pump and a motor (P/M) Regenerative mode: P/M pumps fluid Acceleration: P/M is driven by fluid Many types of pumps and motors, but only a few that fit our application Needs to be low speed, high torque, and variable displacement Pump/Motor GearScrewAxial Piston Radial Piston Vane Variable Displacement High Pressure (5000 psi) Displacement size Pump and motor operation Applicable to HHV No YesNo

Major Components Axial Piston Pump – Odd number of pistons situated parallel to each other rotating around a common shaft Variable Displacement – Displacement can be adjusted to increase or decrease the amount of fluid pumped per revolution Torque=Pressure*Displacement Bent Axis Piston Pump Swash Plate Pump

Major Components Bent Axis Variable Displacement Pump Example 0 deg22 deg45 deg

Major Components Accumulators An energy storage device Two main types: Gas charged and spring loaded During braking, hydraulic fluid compresses an inert gas or spring to store energy Stored energy is then released back to the system when needed Main types of gas accumulators are bladder, diaphragm, and piston Bladder Type Accumulator

Major Components Accumulators Piston Type Diaphragm Type Diaphragm Type Piston Type Bladder Type Pressure to ~5000 psi +0+ Storage Capacity Range -0+ Weight+0+ Safety+0+ Applicable to HHVNoYes

System Modeling Modeling Simulates System Performance Pump efficiencies Operating pressures Flow rates Control system analysis Valve control Advantages Changes in component size/operating conditions can quickly be analyzed Vehicle drive cycle simulation System control integration  Mototron

System Modeling Modeling Software Matlab/Simulink R2007a Matlab/Simhydraulic Hysan

Summary Recapture energy lost through braking Take advantage of wide and varied potential markets Seeking to fill retrofit applications Creating a dynamic computer simulation of system Designing a test bed model for system performance analysis Install and test system in vehicle Special Thanks To: Dr. Kirkpatrick (Advisor-Colorado State University) Dr Guy Babbitt (Advisor-Czero Solutions) Chris Turner (Advisor-Czero Solutions) Staff and Employees of The Engines and Energy Conversion Laboratory Hysan Modeling