Optimizing performance and efficiency of a closed-loop hydraulic power drive under varying load conditions
摘要
The performance and efficiency of closed-loop hydraulic power drives (CHPD) are highly influenced by varying load conditions, making their optimization essential for industrial applications such as mining, manufacturing, robotics, and automotive systems. A key application of CHPD is in chairlift man-riding systems (CMRS), where precise control and energy efficiency are critical. This study focuses on the performance optimization of closed-loop hydraulic drives, specifically examining load-dependent dynamics under two distinct loading conditions: the unilateral loading condition (ULC) and the bilateral loading condition (BLC). Such loading patterns are widely applied to CMRS, which utilizes closed-loop hydraulic drive systems. The research evaluates system behavior across varying operational speeds, analyzing key performance metrics, including total power consumption, efficiency, and the load cycle of the drive unit. A novel real-time optimization framework is proposed to dynamically adjust system parameters, thereby enhancing responsiveness and minimizing energy losses under varying load conditions. Simulations conducted in MATLAB/Simulink® were validated through experimental testing, ensuring accuracy and reliability. Findings indicate that power consumption is higher under BLC than ULC, with increases of 0.8% and 1.7%, respectively. Torque load rises by 1% and 2% under both conditions compared to no-load conditions. Notably, system efficiency improves as the drive speed increases. Under no-load conditions, efficiency rises from 51.08 to 59.64%, while at maximum loading over operational distances of 200 m to 700 m, efficiency gains are substantial. Compared to ULC, the system efficiency under BLC improves from 52.32 to 53.21% at 200 m and from 54.17 to 54.93% at 700 m, both at a speed of 3 rad/s. A similar trend is observed for the speeds of 4 rad/s and 5 rad/s. These findings confirm the effectiveness of the proposed optimization strategies, demonstrating their potential to enhance the operational reliability and cost-effectiveness of hydraulic power drives across various industrial applications. The study provides valuable insights for engineers and practitioners, highlighting the importance of load-dependent optimization to enhance efficiency and reduce energy consumption in closed-loop hydraulic drives.