分腔容积直驱电液控制系统能量高效转换利用的理论与方法

The method driven the hydraulic actuator with direct volume control, and the energy recovery technique to reuse the dynamic and potential energy that conventional system wasted，are the most direct approach and research frontier for electro-hydraulic system to improve the energy efficiency. But by traditional closed loop volume control principle, each pump should be installed with power to match the maximum capacity of its actuator. When used in multi-actuator system, the total installed capacity and costs will be increased. Additional circuit must be added to compensate the cylinder area difference. When used in heavy power system circuit the system will become complicated. As traditional energy recycling process is affected by the nonlinear pressure properties of accumulator, resulting in problems of inefficiency and difficult coordination. So that the range of applications is restricted. For above mentioned reason, the new principle that integrated energy storage element into the separated chambers volume direct driven differential cylinder and active and passive combined hydraulic motor loops are proposed. With new principle the energy efficient transfer and utilization method that combines electro-hydraulic drive and dynamic and potential energy renewable together become possible. In project this new electro-hydraulic control principle along with no throttling losses and dynamic driving potential recycling, power source and load energy-efficient matching will be researched. The research achievements will supply the new theory and principle for the electro-hydraulic control technology to realize the low carbon emissions target to supply the energy on demand. As a general method, system and theory of variable displacement and speed variable controls are both effective, and not limit by the power of the drive. Research has broad application prospects in the electro-hydraulic controlled mobile and industrial automation equipment.

液压泵直驱的容积控制方法、动势能回收利用技术，是提高电液系统能效的最直接途径和前沿方向。传统容积直驱采用闭式回路原理，存在：每台泵需按所驱动执行器峰值流量配置，导致多执行器系统装机容量和成本大幅增加；必须采用辅助回路补偿液压缸面积差；受元件制约，大功率液压缸系统应用受限等问题。另外，传统能量再生方法，为匹配蓄能器压力，需附加节流回路，存在效率低、调控复杂等不足，严重制约这两项技术的应用。为此，提出集成有储能元件的分腔容积直驱非对称液压缸、主被动复合分腔容积直驱液压马达、分腔容积直驱多执行器的电液系统能量高效转换与利用方法，探索可实现无节流损失的驱动与动势能回收利用、驱动与动势能再生一体化、且动力源和负载高效匹配的电液系统节能新原理，为电液控制系统低碳、绿色运行提供先进的理论和方法。研究成果既可用于变转速系统，也适用于变排量控制，且不受驱动功率限制，在电液控制自动化装备中具有广泛应用前景。

液压泵直驱的容积控制方法、动势能回收利用技术，是提高电液系统能效的最直接途径和前沿方向。为解决现有单执行器容积控制技术驱动功率大、非对称流量补偿难、控制特性差，以及传统能量再生方法，为匹配蓄能器压力，需附加节流回路，存在效率低、调控复杂等问题。 提出了集成有储能元件的分腔容积直驱电液系统架构，实现能量无节流损失高效转换和传递，旨在探索可实现无节流损失的驱动与动势能回收利用一体化、且动力源和负载高效匹配的电液系统节能新原理。.为此，项目组设计了使液压缸两腔压力和维持定值的双电机协同总压力控制策略，取得了与阀控系统类似的控制特性，能够四象限驱动负载，仅采用工业上常用的比例控制器就能获得好的控制特性和定位精度，并结合超级电容、蓄能器复合能量回收方式，极大地降低了动力源峰值功率，相较传统阀控系统可降低能耗达80%左右。针对不同的转动惯量范围，设计了单马达主被动复合驱动、双液压马达主被动复合以及阀控分腔容积直驱多种控制方案及策略，消除了回转平台压力波动和回摆现象，在回收能量的同时，改善了系统运行平稳性；最后将其用于液压挖掘机，优化匹配动力源，确定了高能量利用率、高作业效率和运行平稳的单执行器和多执行器协同控制策略，研究了多种复合动作工况下系统的控制特性和能量效率。研究成果既可用于变转速驱动系统，也适用于变排量控制系统，且不受驱动功率限制，在液压电梯、压力机、注塑成型机等大功率工业设备以及挖掘机、起重机等多执行器工程机械中具有广泛应用前景。.项目研究期间，共发表相关学术论文40篇，其中SCI索引期刊13篇，EI索引期刊11篇，国内外会议论文10篇，其中 2篇会议论文获最佳或优秀论文奖，授权美国发明专利1件、国家发明专利8件，培养博士后2名，博士研究生2名，硕士研究生7名，获评“上银优秀机械博士论文奖银奖”1项、“中国煤炭学会青年科学技术奖优秀博士学位论文”1项。