Electric machine sizing consideration for ePumps in mobile hydraulics

Abstract

Abstract Environmental concerns have pushed toward electrified technologies for off‐road vehicle actuations that can lower greenhouse gas emissions and reduce energy consumption. Replacing a central diesel engine with a dedicated electric machine (EM) as a prime mover for the hydraulic supply offers several opportunities for so‐called ePumps (aka electric‐driven pumps) to maximize energy efficiency and limit the usage of electric materials. This paper discusses the impact of different choices for the ePumps architecture (i.e., fixed vs. variable displacement pump; variable speed vs. fixed speed electrical machine), and on their main design parameters in terms of size and efficiency. Although the procedure followed in the study could be extended to different types of electric and hydraulic units, the paper particularly considers ePumps based on permanent magnet synchronous machines combined with axial piston machines. The importance of properly considering the ePump drive cycle and its cooling requirements is taken into account while addressing energy efficiency, mass, and overall compactness of the solution. The results show that an ePump based on a variable displacement pump, when compared to fixed displacement ePumps, reduces the electrical machine size both in volume and mass up to 40%, when the high‐pressure demand is not combined with high flow rate demand, thus decreasing the cost of the EM. In all drive cycles, the variable speed EM–fixed displacement pump architecture has a higher efficiency, ranging from 1% to 5%, compared to the case of fixed speed EM–variable displacement pump. Finally, the paper compares the advantages and shortcomings of each ePump architecture presented, based on representative drive cycles.

Keywords

• actuation systems
• component selection
• electrification
• electrohydraulic unit
• ePump
• off‐road vehicles