Energy Recuperation Research Articles

Hybrid energy storage system topology approaches for use in transport vehicles: A review

AbstractHigh peak current for vehicle starting, recuperation of regenerative braking energy, longer battery lifespan, and more significant acceleration among others in modern transport vehicles (TVs) require increased battery size. Moreover, batteries have high energy density and low power density. Therefore, a big battery pack can weigh more, shorten its lifespan, increase vehicle total mass, and increase battery degradation costs. On the one hand, higher power energy storage systems (ESSs) such as supercapacitors, lithium‐ion capacitors, and superconducting magnetic ESSs have a lower energy density, higher power density, and greater lifespan. Thus, to satisfy the requirements of modern TVs, the combination of higher energy and higher power density can provide enhanced performance and a longer battery lifespan for these vehicles. Available research publications in the literature have addressed a similar problem. However, these publications have reported the findings separately, providing various research and conclusions. Currently, no available literature has compiled an intelligible and combined analysis for addressing hybrid ESS configurations, sizing methods, and energy management strategies to create further knowledge in this domain. There is a need to consolidate a compact and insightful knowledge toward this research direction for a more significant societal and industrial impact. This paper critically reviews the hybrid higher energy density batteries and higher power density ESSs used in TVs. It discusses the integration configurations, applications, and provides sizing methods to achieve the best hybrid energy storage systems (HESSs). Also, applied control methods are described for these HESSs such that the overall system performance matches the vehicle requirements. Lastly, it provides insights and future research direction for HESS configuration, sizing, and control.

Comparison of Dynamic Charge Acceptance Tests on Lead–Acid Cells for Carbon Additive Screening

Including a certain amount of carbon in the negative active material is currently the state‐of‐the‐art method to improve the dynamic charge acceptance (DCA) of lead–acid batteries. The DCA is a key parameter of batteries used in microhybrid cars where brake energy recuperation is implemented. To find the optimal carbon additive, it is essential to test the carbon both in short‐term and long‐term tests. This work investigates the long‐term and short‐term DCA of 2 V, 2.5 Ah lead–acid cells and correlates the results with the external surface area of the carbon. Five different carbons with tailored particle size (27–633 nm) and external surface area (7.1–159.3 m2 g−1) are employed as additives in the negative electrodes. The charge acceptance of cells according to the charge acceptance test 2 (SBA), the DCA (EN) test, and the run‐in DCA test (Ford) is increased via an increase in the carbon external surface area. A correlation between the short‐term tests and the first week of the run‐in DCA test is established for the carbon impact. After several weeks of run‐in DCA test, the carbon effect is diminished and only a differentiation between high and low DCA cells is possible.

МОДЕЛИРОВАНИЕ РАБОЧИХ ПРОЦЕССОВ ЭНЕРГОСБЕРЕГАЮЩЕГО ГИДРОПРИВОДА МЕХАНИЗМА ПОДЪЕМА ЛЕСНОГО МАНИПУЛЯТОРА

At present Russia has adopted a course towards the creation of competitive machinery and equipment. This also applies to mobile manipulator-type forestry machines. Therefore, the design and creation of forestry manipulators with an energy-saving hydraulic drive is an urgent task. The analysis of research of technological, dynamic and kinematic characteristics of manipulator-type machines is given. A new hydrokinematic diagram of the boom lifting mechanism with an energy recuperation system in starting and braking modes is presented. A mathematical model of the boom lifting process has been developed, described by a system of nonlinear differential equations of the second order. Due to nonlinearity, it is impossible to solve the problem in an explicit form; therefore, the finite difference method is used, in which all derivatives are replaced by the corresponding difference analogs. Thus, the original system is reduced to a system of second-order recurrence relations. To solve the relations, the methods of operator theory and functional analysis are used. The sought-for functions are found in the form of a set of points at the nodes of the division of the segment in time. Preliminary calculations using the MathCad program showed that the connection of an energy-saving damping device to the hydraulic drive of the boom lifting mechanism makes it possible to reduce the peak pressure in the hydraulic line of the piston cavity of the hydraulic cylinder during transient modes by 1.5-1.6 times. Bench hydraulic manipulator, made it possible to obtain statistical data on the analysis of the pressure of the system without and with an accumulator, as well as the amount of stored energy per cycle, which amounted to about 30%. The mathematical model of the presented energy-saving hydraulic drive of the forest hydraulic manipulator shows the fundamental possibility of implementing the principle of energy saving during starting and braking modes of loading and unloading operations. Reducing the dynamic loading and energy intensity of the working processes of the boom lifting mechanism of the forestry manipulator by justifying the parameters of the energy-saving damping device of the hydraulic drive allows increasing the reliability of the manipulator, reducing energy costs, as well as the downtime for repairs due to the failure of hydraulic equipment. The results obtained can be used in the design of recuperative systems for other lifting equipment in construction and agriculture

Boom energy recuperation system and control strategy for hydraulic hybrid excavators

In this paper, a boom potential energy recovery hydraulic system for an excavator and its controller is proposed and evaluated. It is a trend in the construction machinery sector to adopt hybrid systems to recuperate potential energy from heavy loads. Many studies have been conducted to improve the efficiency of boom potential energy recovery. However, most of the proposed solutions have limitations regarding commercialization due to low controllability and high cost. The proposed system in this paper uses only electronically controlled hydraulic components. Different operation modes are defined to increase performance, efficiency or a balance between the two. The system is mathematically analysed to derive a control strategy that is able to increase machine efficiency and control performance while maintaining its controllability. The system and control strategy are applied to a prototype machine, a Volvo 30-ton class excavator, to verify the effectiveness of the proposed approach. Experimental results demonstrate that the working cycle becomes around 3% faster, and the fuel consumption becomes around 9% lower than the operation in non-hybrid mode.

Spring accumulators for mechatronic drives with energy recuperation in food industry equipment

Spring accumulators for mechatronic drives with energy recuperation in food industry equipment

Increasing the Efficiency of Recuperation Through the Use of Energy Storage Systems for the Own Needs of Traction Substations

The use of regenerative braking by electric rolling stock on DC railways makes it possible to increase the energy efficiency of the transportation process. The effective use of regenerative braking is associated with creation of conditions for receiving energy obtained through it. For these purposes, rectifier-inverter converters and energy absorbing devices are currently used in the traction power supply system.A promising technology that provides an increase in theefficiency of the use of regenerative braking is energy storage, which allows this energy to be used in the future to cover the traction load curve. A feature of the use of regenerative braking on singletrack sections of DC railways with low traffic intensity is the need to use converters or energy absorbing devices. One of the options for increasing the efficiency of recuperation energy use is the adoption of energy storage systems for the own needs of traction substations. The use of this technical solution is advisable on single-track sections with intensive use of regenerative braking, the effectiveness of which is explained through a decrease in power consumption for own needs of the substation from the external grid.The international research allows us to identify the widespread trend towards the application of electricity storage technology in various fields: from renewable energy sources to electric power systems, including transport power supply systems. International practices demonstrate successful implementation of pilot projects of adoption of energy storage systems for solving problems of increasing the efficiency of electric urban and suburban transport, as well as of metro systems.The objective of the work is to assess the energy performance of energy storage systems when using recovered energy for own needs of a traction substation. The study is based on the methods of mathematical and simulation modelling, optimisation, and mathematical statistics.The discussed issues refer to the use of energy storage systems to provide power supply for own needs of DC traction substations. Main issues of operation of storage systems are considered with the help of a substation case study. The features of the recuperation load curve are described to explain the use of hybrid technologies for developing a storage system. The example of the considered traction substation helps to demonstrate the solution to the problem of determining main parameters of the storage system, considering the specifics of operation of electrochemical and electrical modules.

Flotation separation of poly (ethylene terephthalate and vinyl chloride) mixtures based on clean corona modification: Optimization using response surface methodology.

Postconsumer polyethylene terephthalate (PET) has potential applications in many areas of manufacturing, but contamination by hazardous polyvinyl chloride (PVC) in common waste streams can reduce its recyclable value. Separating collected PET-PVC mixtures before recycling remains very challenging because of the similar physicochemical properties of PET and PVC. Herein, we describe a novel flotation process with corona modification pretreatment to facilitate the separation of PET-PVC mixtures. Through water contact angle, surface free energy, X-ray photoelectron and FT-IR characterization, we found that polar hydroxyl groups can be more easily introduced on the PVC surface than on the PET surface induced by corona modification. This selective wetting can suppress the floatability of PVC, leading to the separation of PET as floating product. A reliable mechanism including two different hydrogen-abstraction pathways was established. Response surface methodology consisting of Plackett-Burman and Box-Behnken designs was adopted for optimization of the combined process, and control parameters were solved based on high-quality prediction models, with fitting from significant variables and interactions. For physical or chemical circulation strategies with PET purity prioritization, the validated purity of the product reached 96.05% at a 626W corona power, 5.42m/min passing speed, 24.78mg/L frother concentration and 286 L/h air flow rate. For the energy recuperation strategy with PET recovery prioritization, the factual recovery reached 98.08% under a 601W corona power, 6.04m/min passing speed, 27.55mg/L frother concentration and 184 L/h air flow rate. The current work provides technological insights into the cleaner disposal of waste plastics.

Electro-Hydraulic Drive of the Variable Ratio Lifting Device under Active Load

Hydraulic systems fed by fixed displacement pumps driven by frequency-controlled electric motors can replace conventional throttling systems due to their ability to control the speed of hydraulic cylinders regardless of the value and direction of the load. These systems can improve the energy efficiency of the drive or even provide the possibility of energy recuperation during lowering. This paper presents experimental studies of the new drive system with volumetric control of the speed of the lifted/lowered payload using the example of a scissor lift. The system uses a reversible gear pump driven by an asynchronous motor fed by a frequency inverter operating in field-oriented control mode. Comparative studies of the mapping of the assumed speed of the hydraulic cylinder and platform are presented, as well as studies of the influence of the load change on the speed and positioning of the mechanism driven by the open-loop controlled system.

Passive Perching with Energy Storage for Winged Aerial Robots

Perching in unmanned aerial vehicles (UAVs) offers the possibility of extending the range of aerial robots beyond the limits of their batteries. It has been a topic of intense study for multirotor UAVs. Perching in winged UAVs is harder because a kinetic energy balance has to be struck. Reducing too much energy results in the vehicle stalling and falling. Too much kinetic energy at touchdown could damage the vehicle. Most studies used dangerous pitch‐up maneuvers to manage this balance. This work presents a system that eliminates the pitch‐up maneuver by mechanically capturing and storing kinetic energy at impact. It is validated using a passive mechanical system consisting of a storage mechanism for energy recuperation and a claw for perching on a horizontal rod. The energy stored in the mechanism is then used to unperch. The mathematical model for the recuperation strategy is presented and perching success at various approach attitudes are characterized. The proof‐of‐concept claw recaptures 5% of the kinetic energy during perching. Experiments indicate that the device can successfully perch at a wide range of yaw angles, but requires more precision in roll. We show that our perching mechanism enables the fastest UAV perching to date (7.4 m s−1).

Energy model of transport machines with braking energy recovery

Most of the time, modern transport vehicles operate in unsteady modes. Undoubtedly, the reasons for the decrease in the efficiency of machines are fluctuations in speed and load, their deviations from the optimal values cause an increase in energy losses. Another reason for the increase in energy losses is the process of forced braking when it is necessary to stop the car. A class of vehicles with hybrid propulsion systems that can recover braking energy are currently being developed. Significant advantages among them are transport vehicles with a flywheel energy storage, which have a long service life. This article discusses the energy model of transport vehicles with the possibility of braking energy recuperation.

Influence of basic carbon additives on the electrochemical performance of lead-carbon batteries

Enhancement of the dynamic charge acceptance (DCA) of advanced lead-acid batteries for micro- and mild-hybrid cars is essential to improve the fuel consumption and CO2 emissions by recuperation of the braking energy. In this work, the effect of carbon surface basicity on the electrochemical activity and the DCA of lead-carbon electrodes is revealed. Five different activated carbons (AC) with different pH values ranging from 9.5 to 11.1 were prepared by ammonia and hydrogen gas treatments. These ACs were used as additives in the negative electrodes of 2 V lead-acid cells. The cyclic voltammetry of the pure carbon as well as lead-carbon (negative) electrodes demonstrates that the hydrogen evolution reaction (HER) activity is increased via higher surface basicity of the ACs. A correlation between the surface basicity of carbon and the DCA can be established in the electrochemical performance. A remarkable impact of carbon pH on the charge currents after the charge history (Ic) as well as final DCA (IDCA) is observed. In case of the charge currents after the discharge history (Id) and during simulated Stop/Start microcycles (Ir), the carbon content in the negative electrodes affects the charge currents. This work demonstrates that the DCA of advanced lead-carbon batteries can be improved by using carbon additives with higher pH in the negative electrodes.

COMBINED POWER PLANT OF A MOTOR VEHICLE

Currently, the most promising areas of development of motor transport are an increase of the horsepower characteristic of their power plants as well as increase of fuel efficiency, and reduction of the toxicity level of exhaust fumes. An internal combustion engine as a power unit of the car in a number of operation modes (supplemental motion, small work load, idling, etc.) works extremely inefficiently and contains the high concentration of harmful components in the exhaust fumes. Additionally, in a context of growing shortage of carbohydrate fuels and increase in their value, the problem of the fuel-burn improvement is especially acute. To improve the environmental compatibility and efficiency of power plants of the vehicles, combined cycle power plants are used. One of the most important problems that the machine construction faces is the creation of environmentally friendly and economical power plants. A hybrid power plant, which contains several power units operating on different physical principles, is proposed by the authors. The main power unit uses the energy of liquid or gaseous fuel in the mode of an internal combustion engine; the auxiliary power unit which is made as a reverse volumetrical driving machine with swinging motion of the work tools (forcers or blades), uses air power which comes from a pneumocylinder through a cooler and / or pneumatic air tank. The auxiliary power unit is equipped with a reversible invertor of the driving direction, made on the basis of a spherical slider-crank mechanism. This insures the operation of the auxiliary power unit in the mode of a pneumatic motor or compressor in accordance with the algorithm generated by the electronic control unit of the combined power plant of the vehicle. To utilize the heat energy of the exhaust fumes of the main power unit, the combined power plant is additionally equipped with a Stirling engine or steam generation module and a steam engine; in order to break energy recuperation of the vehicle it is additionally equipped with a hydraulic or electrodrive. Naturally, when choosing the specific forms of application of combined cycle power plants, any combinations of auxiliary power units are possible. They can be supplemented and / or specified based on the knowledge of specialists. Combined cycle power plants are technically complete solution. Their industrial applicability is obvious and is substantiated by experiments. Nowadays, the creation of a combined cycle power plants of a vehicle, which are a combination of several engines operating on different physical principles is the task of great economic importance. Combined power plants this allows to reduce fuel consumption per 100 km significantly, increase energy potential, horsepower characteristic and improve the environmental performance of the vehicle. The work is planned to be continued in the direction of optimization synthesis of auxiliary power units that work on different physical principles.

Magnetic circuit optimization of linear dynamic actuators

<p class="Abstract">Contactless braking methods (with capability of energy recuperation) are more and more widely used and they replace the traditional abrasive and dissipative braking techniques. In case of rotating motion, the method is trivial and often used nowadays. But when the movement is linear and fast alternating, there are only a few possibilities to break the movement. The basic goal of research project is to develop a linear braking method based on the magnetic principle, which enables the efficient and highly controllable braking of alternating movements. Frequency of the alternating movement can be in wide range, aim of the research to develop contactless braking method for vibrating movement for as higher as possible frequency. The research includes examination and further development of possible magnetic implementations and existing methods, so that an efficient construction suitable for the effective linear movement control can be created. The first problem to be solved is design a well-constructed magnetic circuit with high air gap induction, which provides effective and good dynamic parameters for the braking devices. The present paper summarizes the magnetostatics design of “voice-coil linear actuator” type actuators and the effects of structure-related flux scattering and its compensation.</p>

Prototype production and comparative analysis of high-speed flywheel energy storage systems during regenerative braking in hybrid and electric vehicles

In conventional EVs and HEVs, only a small part of the vehicle's kinetic energy can be usefully stored during deceleration. Generally, this storage process can be done by providing energy flow to the main battery of the vehicle. Since batteries work with a chemical reaction, they are not suitable for fast charging and discharging required for regenerative braking. In this case, a fast storage system is needed to store the regenerative braking energy in a short time. As a solution, the flywheel energy storage system (FESS) can be offered.In the literature, power transmission of vehicles with integrated FESS is provided by mechanical systems (CVT FESS). These systems are heavy, high cost, large volume, and occupy the rear axle of the vehicle.In the proposed system, a purely electrical power transmission is proposed to store the kinetic energy of the vehicle in FESS. In developed topology, the traction machine of the vehicle is also used as a generator, and the recuperation energy is stored in the electrically driven (M/G) FESS.As a result of the experimental studies, a minimum of 56% energy recovery efficiency was obtained. In addition, it has been shown that the developed system is 30% lighter, occupies 60% less space in volume, is at least 50% more cost-effective, maintenance-free, and has fewer moving parts compared to the CVT FESS.As a result, the addition of a fast-response secondary energy storage system to the electric vehicle battery contributes to the increase in efficiency.

Comparing the physical principles of action of suspension damping devices based on their influence on the mobility of wheeled vehicles

This paper reports the comparison of two physical principles of action of suspension damping devices based on their influence on the mobility indicators for an 8×8 wheeled machine. A radical difference between these principles of action is the dependence of resistance forces on the speed of the relative movement of working bodies (internal friction: hydraulic shock absorbers) or on the relative movement of working bodies (external friction: friction shock absorbers). Widespread hydraulic shock absorbers have certain disadvantages that do not make it possible to further increase the mobility of wheeled or tracked vehicles without the use of control and recuperation systems. In turn, in friction shock absorbers, the use of new materials has eliminated many of their shortcomings and thus can provide significant advantages. It was established that the application of friction shock absorbers for a given wheeled vehicle did not significantly affect the speed compared to hydraulic ones. The main factor that prevented the implementation of the advantages of friction shock absorbers was the insufficient suspension travel. However, friction shock absorbers absorbed 1.76...2.3 times less power, which reduced the load on nodes and increased efficiency (autonomy). In addition, a more uniform load on suspensions was ensured, which improved their resource, and, due to the prevailing vertical oscillations of the suspended body over the longitudinal-angular ones, the geometric passability improved as well. The comparison of two physical principles of action of damper suspension devices in a wheeled vehicle has shown that the use of friction shock absorbers could provide significant advantages in resolving the task relates to improving the mobility and would fundamentally affect the choice of the suspension energy recuperation system if it is applied.

Ensuring the Continuity of Power Supply to the On-Board Auxiliary Devices of the Trolleybus through the Recuperation of Kinetic Energy

When a trolleybus travels through insulated sections of the overhead contact line, it experiences momentary power interruptions, which adversely affect the vehicle’s on-board auxiliary subassemblies. To reduce these negative effects, one can harness energy recovered via regenerative braking. A model power supply circuit diagram for structural systems of the trolleybus is proposed. Simulation tests were carried out to develop a method for analyzing power supply to trolleybus auxiliary devices and verify it in a real-life example. The results allow determination of the limit power that can be generated by the trolleybus drive system to feed auxiliary devices during interruptions in power supply from the overhead contact line. The possibility of powering the on-board auxiliary equipment of a trolleybus using energy from recuperation with a traction motor is presented.

Regenerative braking energy recuperation from urban electrified train operation by active rectifier

With a large capacity, the total energy consumption for electrified train operation of the urban railway system is very high. Therefore, energy-saving solutions are very meaningful to retain their outstanding advantages compared to other means of transportation. Recovering regenerative braking energy is the potential solution to improve energy efficiency. This paper proposes a solution to recover regenerative braking energy by an active rectifier installed at a traction substation capable of bi-directional energy flow. In the braking phase, the motor operates as a generator that returns energy to the utility source. Thanks to the active rectifier, regenerative braking energy will be returned to the source without being burned on the braking resistors. The energy efficiency of this solution is verified by simulation results on Matlab Simulink software with simulation data collected from Cat Linh-Ha Dong urban railway, Vietnam. Evaluating the level of energy savings in the cases with/without active rectifiers showed that using the active rectifier had saved 4.4% of the total traction electric energy.

Energy saving in rail transport

Aim of this article is to introduce and present advantages and possibilities of using simulation tools to calculate energy flows of tractive vehicle in all phases of its ride. The focus is on the braking phase, especially on the braking energy recuperation that offers the highest energy saving potential.Energetic simulation was carried out as a part of a current railway reconstruction study, which is a good example of possible energetic calculation use. Energetic calculation in the simulation are performed using so called "exact method" developed at the Faculty of Transportation. The advantage of the method is that it provides a high degree of accuracy. Due to the simulation calculation being performed in real-time, the user can enter the calculation even during the simulation. Crucial part ofevery simulation are quality input data, such as vehicle braking characteristic (including all working points below the envelope line together with the efficiency characteristics of the power train parts (engine, transmission, convertor and others)). Also, sufficiently precise (with a precision of 1 meter) railway track details (detailed geometrical and other information on the current and reconstructed railway track or on the railway track proposal.To present savings during the ride, the railway track section on the track Montreál-Sherbrooke was chosen. On this track, (especially electrification and partial reconstruction of the superstructure) is planned. Reconstruction level will be dependant on the local economical and social conditions. However, in the most optimistic case, total electrification of the track will be undertaken, or lower level of the reconstruction when the vehicles that have very similar characteristics. The railway track section is located between the cities of Montreál and Sherbrooke, that are 160 km apart. To compare the current, and possible future, state, comparison of energy consumption of the vehicle was conducted on the same track with the same geometrical characteristics.We can assume that the overall energy intensity of the ride on the newly reconstructed track (eg. with greater radius of the arches) will be lower than the overall energy intensity of the ride on the track before reconstruction. Current data on energetic consumption are not available, therefore they were obtained by simulation and verified by calculations and considered sufficiently accurate.Presumably, the input simulation parameters required for the simulation will not always be delivered in the sufficient quality or will be partly missing completely. In these cases they will be substituted by various algorithms, that can be machine-processed and that are part of the simulation calculations. One of the crucial algorithms is so called "moment efficiency". Its machine processingis not entirely developed and therefore, this simulation will be conducted without its usage. For financial reasons, simulation calculation was verified only by the theoretical physical calculation method. Based on several partial results, emergent computing tool is functional and sufficiently accurate. The simulation program is supposed to be experimentally verified after its finishing.The outcomes presented in this article are calculated by simulated computation and were not confronted with the real situation in any way. However, relevant calculation algorithms, processes and theoretical background of the simulation were already verified on the older software versions. Therefore, the simulated outcomes are supposed to be at least sufficiently accurate to provide preliminary study for the railway reconstruction. Presented calculations were executed by using author’s simulation software.Part of the methodology was taken from the previous, already verified, versions of the software for vehicle ride simulation.

Simulation of induction motors with energy recuperation for lifting mechanisms of non-ferrous metallurgy enterprises

Simulation of induction motors with energy recuperation for lifting mechanisms of non-ferrous metallurgy enterprises

A regenerative braking energy recuperation from elevator operation in building by active rectifier

Elevators- means of vertical transportation to carry people and goods are an indispensable part in offices, high-rise buildings, hospitals, commercial areas, hotels, car-parks when blooming urbanization develops worldwide. However, the level of energy consumption in elevator operation is significant, so energy saving solutions have been outlined and applied in practice. With frequent braking phases, regenerative braking energy is wasted on braking resistors. Therefore, this paper proposes regenerative braking energy recuperation method for elevator operation in building by active rectifiers enabling the braking energy to be fed back into utility grid. Simulation results conducted by MATLAB with data collected from OCT5B building-RESCO new urban area, Ha noi, Vietnam have verified saving energy of using active rectifiers replacing diode rectifiers up to 33%.