2012 Energy Efficient Hydraulics and Pneumatics Conference
Energy Saving Technologies for the
Mobile Equipment Industry
Steve Zumbusch, Director – Application and Commercial Engineering
© 2012 Eaton Corporation. All rights reserved.
Changing Value Landscape
• Previously
• Emphasis on Installed Costs
• Simple, Fixed Displacements
• Conventional Manifold Designs
• Technology Solutions
• Hard to Justify for Operating Cost Savings…
© 2012 Eaton Corporation. All rights reserved.
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Changing Value Landscape
• Today:
• Installed Costs Still Important
• Focus Now on Total System Cost
• If Improvements Can Be Delivered…
• Justification for Adding Technology
• Power on Demand Systems
• Electro Hydraulic Solutions
• Integrated System Designs …
© 2012 Eaton Corporation. All rights reserved.
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How to Gain Improvements?
• Complete System Review
• Look at All Existing Sub-Systems
• Individual Areas Consuming Power
• Look For Overall System Needs
• Alternate Ways to Achieve Mission
• Sources Of Power Loss:
• Parasitic Losses
• Efficiencies
• Standby Losses
• So Let’s Look at a Few…
© 2012 Eaton Corporation. All rights reserved.
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General: Pressure Drops
• Pressure Drops Can Occur in 2 Areas
• Fluid Conduits (Hose, Fittings, Tubing, …)
• Hydraulic Components (Valves, Pumps, Motors, …)
• Product Selection Critical
• Products Designed For Different Criteria
• Higher Starting Torques
• Lower Pulsations
• Quiet Operation
• Etc.
• Example: No Load Pressure Drop in Hydraulic Motor…
© 2012 Eaton Corporation. All rights reserved.
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Example: Proper Product Selection
• Product Selection Critical
• No Load Pressure Drop in Hydraulic Motor
• New Technologies Used in Component Designs
• New Motor Designs Target Specific Goals
• Starting Torque
NLPD Comparison, (2-speed motors in HSLT)
• Pulsations
800
• No Load
Pressure Drop
• Etc…
Pressure Drop (PSI)
700
600
500
400
300
200
Eaton
HP30 2-spd
100
0
0
5
10
15
20
25
30
35
40
45
Flow (GPM)
© 2012 Eaton Corporation. All rights reserved.
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No Load Pressure Drop
• Example Hydraulic Motors
Pressure Drop (BAR)
• No Load Pressure Drop = Parasitic Loss (Power Loss)
• Worse at Cold Temperatures
NLPD Comparison, (2-speed motors in HSLT)
50
40
25 ΔBar
(360 ΔPSI)
30
5.5 kW (7.4 HP )
20
Power Loss Reduction
Eaton
HP30 2-spd
10
0
0
20
40
60
80
100
120
140
160
Flow (LPM)
© 2012 Eaton Corporation. All rights reserved.
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System Pressure Selection
• Systems Moving to Higher Pressures
• 210 Bar → 280 Bar → 420 Bar
• Why?: Power = Flow x Pressure
• Parasitic Losses Increase as Flow2
For Same Power:
145 LPM x 140 Bar
-or72 LPM x 280 Bar
Results…
Savings of 10 kW (14 HP)
at 72 vs 145 LPM
Parasitic Loses
System Parasitic Losses vs Flow
50
40
30
20
10
0
0
20
40
© 2012 Eaton Corporation. All rights reserved.
60
80
100
Flow
8
120
140
160
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Fan Drives
• Traditional Mechanical Drive Systems
• Sized For Cooling At Idle
• Excess Power At High Speeds (Lost Power)
(Power to Fan → RPM3)
• Hydraulic Fan Drive Advantages
• Easier To Mount Fan In Best Real Estate
• Tighter Mounting To Shrouds (Better Efficiency)
Power to Fan
• Significant Power Savings
At High Speeds…
Fan Power vs Engine Speed
0
500
© 2012 Eaton Corporation. All rights reserved.
1000
1500
2000
2500
9
3000
Engine Speed
3500
4000
9
Propel Solutions: Hydrostatics
• “Automotive Drive”
• Simplified Operator Control
• Electronic Versions – More Capabilities
• Match Engine Power Curves
• Consistent Performance Hot/Cold
Vehicle Speed
Pump Displacement
Displacement vs Engine Speed
Same Speed Achieved
But…
With Less RPM, More Displ
0
500
1000
1500
2000
2500
3000
3500
4000
Engine Speed
© 2012 Eaton Corporation. All rights reserved.
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Propel / Circuit Solutions
• “Anti-Stall”
• Prevents Demands Beyond Power Available
• Improved Fuel Efficiency
• Better Productivity
• Reduces Wear/Tear on Starters
• Electronic Versions
• Optimize for All Throttle Settings
• More Custom Controls Possible from Vendors…
© 2012 Eaton Corporation. All rights reserved.
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Work Circuits
• Historic Method: Fixed Displacement
• Puts Out Full Flow All The Time
• Bleed Off What Is Needed
• Common Across Many Areas
• Steering, Work Circuits, Transmission Lube, …
Eaton
Gear Pumps
• Power Loss Can Be Significant
• Especially At Low Flow/High Pressure
Example: If Need is 8 LPM @ 200 Bar…
… but system puts out 80 LPM
… 24 kW (32 HP) Loss
© 2012 Eaton Corporation. All rights reserved.
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Work Circuits: Power on Demand
• Better System: Variable Displacement
• Varies Flow Based on Demand
• Maintains Pressure in Circuit
• Best System
• Intelligent Pump and Valve Work Together
Eaton x20 Series
Piston Pump Family
• EH System Provides Only Flow Required
• Smart Valve Directs Flow Where Needed
Eaton Ultronics
EH Valve
© 2012 Eaton Corporation. All rights reserved.
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Load Leveling Systems
• Complex Systems Power Management
• Opportunities for Specialized Circuits
• Store Energy to Level Out Peak Demands
• Intelligent, Pressure Compensated Valve
• Capability to Proportionally Divide/Share Flow
• Operate from Pressure Rail/Accumulator
• Already Used in Industrial Applications
Eaton Ultronics
EH Valve
© 2012 Eaton Corporation. All rights reserved.
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Adding Brains – Electro Hydraulics
• Critical Technology for Significant Savings
• Ties Intelligence To Key Areas
• Engine Power Management
• Hydraulic “Smart Components”
• Operator Interface (Controls/Displays)
Eaton HFX
Controllers
© 2012 Eaton Corporation. All rights reserved.
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© 2012 Eaton Corporation. All rights reserved.
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