Team 4
Senior Design Final Presentation
May 7, 2011
Liz Kladder Jay Prins Zach Talen Tim Bangma Jon Mulder
Outline
 Project Introduction
 Hybrid Technologies
 Our Hydraulic System
 Prototyping
 Testing
 Results
 Business Plan
 Conclusions
Project Introduction
Context  Efficient energy usage
Problem  Inefficient vehicle use can be unavoidable in
some applications
Solution  Improve efficiency with the hydraulic hybrid
system
Overall Project Goal
Validate Hydraulic Hybrid System can increase stop and
go fuel efficiency by 40%
Design Norms
Stewardship
Transparency
Caring
Hybrid Technologies
 Electric
 Toyota Prius
 Flywheel
 Formula 1
 Hydraulic
 UPS
Benefits of a Hybrid System
 Regenerative braking
 Optimal engine performance
Power per Fuel Flow [hp/(gal/hr)]
 Decreased brake maintenance
Power per Fuel Flow
Rate vs Engine rpm
14.8
14.6
14.4
14.2
14.0
13.8
13.6
1800
2300
2800
Engine Speed [rpm]
3300
Benefit of Hydraulic Hybrids
 Less energy conversions
 Electric
 Hydraulic
Two Types of Systems
Series
Parallel
www.Eaton.com
Hydraulic System
Hydraulic System: Accelerating
Hydraulic System: Coasting
Hydraulic System: Braking
Prototypes
 Base Case
 Hydraulic Hybrid
Base Case Cart: Frame
Base Case Cart: Gas Engine Mounting
Base Case Cart: Drive Train
Hydraulic Hybrid Cart
 Removed base case drive train
 Retrofitted cart with hydraulic components
 Hydraulic Pump
 Hydraulic Motor
 Accumulators
 Reservoir
 Hydraulic Valves
Hydraulic Hybrid Cart
Reservoir
Hydraulic Pump
Accumulators
Flow Control Valves
Hydraulic Motor
(www.grainger.com)
Other Components
 Redundant Brakes
 Hydraulic
 Mechanical
 Linkages
 Gas pedal
 Brake pedal
Hydraulic Hybrid Retrofit Costs
Component
Cost
Eaton Hydraulic Pump
$246.50
Accumulators Inc. Accumulators
$3286.00
7 gal. Reservoir
$100.00
Haldex Hydraulic Motor
$200.25
Misc. Hydraulic Valves
$843.00
Misc. Hoses and Fittings
$550.00
Mechanical Couplers
$60.00
Pressure Fixtures
$1000.00
Total
$6285.75
Test Procedure
Testing Video
Results
Base Case Cart Hydraulic Hybrid Cart
Stop and Go Fuel Economy
13.9 mpg
21.1 mpg
52.4% increase in average stop and go fuel economy
Improvements
 Different pump or hydraulic motor
 Variable displacement motor
 Check valves with lower cracking pressure
 Design to eliminate minor losses
Business Plan
 Target Market
 Package delivery, garbage trucks, city buses
 Introduction to the market
 O.E.M.
 Retrofit is to expensive
 Potential Savings
 Higher gas mileage, lower maintenance costs
Business Plan
 Feasibility
 High cost on prototype
 Pay back period is 19 years at current gas prices ($4.20)
Longer than the life of the vehicle
Vehicle Payback Based on Gas Price
25
Lifetime of Vehicle (years)

20
15
10
5
0
$0.00
$10.00
$20.00
$30.00
$40.00
Gas Price per Gallon ($)
$50.00
$60.00
Obstacles
 Budget
 Time
 Experience with Hydraulic Systems
 Component Failure
Conclusions
 Met our goal!
 Met efficiency expectations
 Proved our system works
 Very expensive system
 Learned a lot
 Had fun!
Acknowledgements
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Matt Mills & Kelly Dawley – Vermeer Corporation
Vermeer Charitable Foundation – Financial Support
Ned Nielsen – Team Advisor
Ren Tubergen – Industrial Consultant
Phil Jasperse – Calvin College Metal Shop
Charlie Huizinga – Calvin College Physical Plant
Bond Fluidaire, Inc – Hydraulic hose and fittings
Great Lakes Fluid Power – Accumulator Charging
Rex Sheler – Decals
Mike Harris – Donor Acquisition
Jim Kuipers – Cart Donation
Family and Friends
Questions?