PROJECT DESCRIPTION
BACKGROUND
In power transmission mechanics, hydraulic systems are unique due to their high-power density and compactness. Piston pumps, a key element in hydraulic systems, are widely used due to their high working pressure and large flow. They represent the biggest market share among hydraulics and were projected to reach 36 million units globally in 2023.
Original equipment manufacturers of heavy-duty machinery are facing global competition and strict environmental regulations that demand more efficient technologies. The construction sector is responsible for over a third of global energy consumption and nearly 40% of total direct and indirect CO2 emissions. Moreover, heavy-duty machines operate in harsh environments and face aggressive loading conditions over a long running time.
Hydraulic cylinders play a key role in meeting the demand for technological upgrades and compliance with environmental standards. While low-pressure hydraulic cylinders are bulky, fully high-pressure systems are inefficient because full power is not needed all the time and in all work functions. State-of-the-art solutions incorporate external pressure amplifiers adding system complexity, raising costs and increasing energy consumption.
Additionally, hydraulic systems use large amounts of harmful hydraulic fluids. Although sealing technologies have advanced considerably over the past 30 years, the development of hydraulic system operating pressures and response times has led to greater leakage. It is estimated that 370 million litres of oil leak from hydraulic equipment every year.
OBJECTIVES
The project’s specific objectives were to:
- integrate the power cylinders (PCs) into different types of demolition tool excavator attachments
- demonstrate PCs technology on an artificial test site under controlled conditions and on real demolition sites (for 50 hours per attachment)
- evaluate the optimisation potential and to validate the technology
- monitor all relevant environmental and health parameters such as the reduction of fuel consumption, resource efficiency, oil consumption, noise, dust, safety, etc.
- start with 4 replications during the project and prepare replication strategy for more applications
- prepare the transfer of cartridge amplifiers (Cas) from high flow (HF) to low-flow (LF) cylinders and demonstrate the adaptability to other applications
- promote the increase of operational safety for workers
- disseminate the project results and to raise public awareness of the advantages of PCs over conventional hydraulic cylinders.
RESULTS
The project achieved its objectives. In particular:
- a higher force can be applied only when needed, resulting in a reduction of overall energy consumption by 15-20%
- the same work can be done 10% faster and tools with integrated PC will do the same job with smaller excavators, resulting in less fuel consumption and greenhouse gas (GHG) emissions: during the demonstration phase, a total of 5.5 tonnes of CO2 savings were achieved
- PCs reduce the use of materials: the amplification ratio, from 2 up to 2.8, allows a reduced rod diameter and reduces overall weight by allowing for smaller components (up to 15% reduction)
- 10% less overall noise exposure was obtained
- 7% less dust production has been estimated due to the use of the project’s system in demolition works
