Search Results (4)

The development of the open-pit mining industry has set higher performance standards for mining electric shovels. Addressing issues such as low efficiency, high energy consumption, and high failure rates in working mining electric shovel devices, this paper comprehensively considers bulk mechanics, structural mechanics, and dynamics to conduct a multidisciplinary, collaborative design optimization for electric shovels by introducing the BLISCO method, which is based on an approximated model, into the structural-optimization design process of working electric shovel devices, aiming to enhance the overall performance of electric shovels. Firstly, a dynamic model of an electric shovel is established to analyze the hoist force and crowd force during the excavation process, and an accurate load input for the dynamic analysis is provided through the bulk material mechanics model. Additionally, to ensure that the stiffness of the boom meets the requirements, the maximum stress at the most critical position of the optimized boom is considered. Subsequently, the design variables are screened through experimental design, and an approximate model is established. Focusing on the hoist force, crowd force, maximum stress at the critical position of the boom, and the angle between the dipper arm and the wire rope, a mathematical model is constructed and optimized using a two-level integrated system co-optimization framework based on an approximate model (BLISCO-AM), followed by a simulation. Finally, a test bench for the electric shovel working device is constructed to compare pre- and post-optimization performance. Experimental results show that through the optimized design, the hoist force and crowd force required in a single excavation process are reduced by 6% and 8.48%, respectively, and the maximum angle between the wire rope and the dipper arm is increased by 4%, significantly improving excavation efficiency while ensuring the safety and reliability of the equipment. Full article

The potential energy recovery of hydraulic excavators is very significant for improving energy efficiency and reducing pollutant emissions. However, the more common solutions for potential energy recovery require more energy conversion processes before these potential energies can be reused, which adds to the complexity and high cost of the system. To tackle the above challenges, we proposed a novel energy recovery system for hydraulic hybrid excavators based on the digital pump with an energy recovery function. The new system could operate in three different modes: pump, energy recovery, and direct reuse. Based on the descriptions of the working principle of the digital pump and the whole energy recovery system, the mathematical models of the digital pump, the excavator arm cylinder, and the accumulator were established and the AMESim simulation model (combining mechanics, hydraulics, and electrics) was developed. The dynamic characteristics of the energy recovery system were studied under no-load and full-load conditions. The simulation results showed that this scheme could achieve 86% energy recovery when the boom was lowered and reused the recovered energy directly when raised, which could decrease the system input energy by 78.1%. This paper can provide an optimized solution for construction machinery or off-road vehicles and presents a reference for the research on digital hydraulics. Full article

An autonomous excavator can be a good solution in the construction industry to deal with existing issues such as high labor costs and harsh and hazardous environmental conditions. To increase energy efficiency for autonomous excavators, this study proposes two approaches. First, a new and unique design with parallel arm and bucket actuators is proposed for an electric excavator manipulator. Since the three actuators of the boom, arm, and bucket are in series for the conventional design of excavators, it is difficult to share external loads between them. However, a parallel configuration of the arm and bucket actuators in the proposed new design can facilitate load sharing and overcome higher external loads. By replacing hydraulic actuators with electric linear actuators, this design also reduces energy consumption during idling. Moreover, with low back drivability, the electric linear actuators can handle relatively high external forces without spending energy while not in motion. Secondly, a PSO-based path-generation algorithm was developed for autonomous excavation to minimize energy consumption while avoiding collisions with unwanted obstacles. In the PSO algorithm, it is possible to change the priorities of the elements to the minimum by adjusting the gains in the cost function. Two scenarios—scenarios with and without considering energy saving—were considered to test the performance of the developed algorithm, with the results between the scenarios compared. Simulation results show that the proposed algorithm reduces energy consumption in each digging cycle by 18.51%. Full article

The hydraulic accumulator has the advantages of high power density, fast response, stable operation and high cost performance. However, compared with the electric energy storage method, the hydraulic accumulator has low energy density and large pressure fluctuation while absorbing and discharging energy, which severely limits its application in hydraulic excavators. To improve the potential energy loss of the boom during the lowering process, an electro-hydraulic drive and energy recovery system for excavator booms (EHDR-EEB) based on a battery and accumulator is proposed. As a result, a simulation model of the electro-hydraulic drive and energy management strategy of a 1.6 t pure electric hydraulic excavator is built to investigate the energy regeneration and utilization. The simulation outcomes show that the potential energy recovery rate is as high as 92%. This research on EHDR-EEB makes a significant contribution to the economic improvement of electric hydraulic excavators. Full article