Hybrid Wheel Loader
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A DEUTZ four-cylinder engine of the 2011 series is used with a power output of 36.9 kW at a speed of 2100 min-1. Flywheel and flywheel housing are replaced with a very compact and powerful electric unit. The efficiency of this permanent-field synchronous unit is well above 90 percent. In view of the high power density electric unit and power electronics are oil-cooled. The electric unit has a rated power of 10 kW and a peak power of 30 kW.
HEINZMANN, a well-known manufacturer of engine control systems and for several decades a DEUTZ partner and supplier, will develop and manufacture the electric unit and power electronics. Thanks to their modular construction concept, these components can also be installed in other types of equipment. Installation of the hybrid power unit in the wheel loader does not involve any problems, as the diesel engine with integrated electric unit is just negligibly longer than the original diesel engine.
A Li-Ion battery, developed and manufactured by Axeon specifically for this project and based on DEUTZ and WEYHAUSEN specifications, serves as storage element. During the first development stage of the hybrid power unit the following system functions will be realized:
• Start and stop: automatic engine stop during idling phases, automatic engine start in the case of continued operation, the usual starter is omitted.
• Power boost: in the case of power peaks, the electric unit is cut in.
• Battery charging: if the diesel engine has excess power, the electric unit can charge the battery while operating as generator.
• Recuperation: part of the braking energy is refed into the battery by the electric unit.
This system will be installed and tested in a WEYHAUSEN wheel loader of type ATLAS AR 65-Hybrid. At this development stage of the power unit all functions on the equipment side are still hydraulically driven. In a next step the wheel loader shall be powered by a full hybrid drive system. It will then be possible to realize in addition to the above functions temporarily a strictly electric, and thus emission-free operation.
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Hybrid Wheel Loader
First hybrid power unit for construction equipment
Innovation from DEUTZ, WEYHAUSEN and HEINZMANN
With the presentation of a hybrid power unit for a wheel loader from WEYHAUSEN DEUTZ AG, Cologne, has set at bauma 2007 in Munich once again standards for construction equipment drives.
With this first project worldwide that will be realized in close cooperation with HEINZMANN and WEYHAUSEN, the project partners intend to present innovative, future-oriented drive solutions. The systems hitherto known for passenger cars and commercial vehicles provide promising results with fuel consumption savings up to 30 percent. It is intended to utilize this potential in the construction equipment sector as well. In the face of requested CO2 emission limitations hybrid power units might substantially contribute towards reducing CO2 emissions.
Usually, hybrid drive systems consist of a combustion engine, conventional drive elements, such as transmission, axles and hydraulic system, at least one electric power unit (motor-generator), power electronics and a heavy-duty battery. When operated as motor, the electric unit withdraws energy from the battery and feeds it into the power train. Vice versa, when operated as generator, the electric unit withdraws power from the power train and recharges the battery. Power peak demands can thus be covered by the battery. The combustion engine can therefore be downsized and be operated at its best operating point. This results in a considerably improved efficiency of the complete equipment drive.
At the initial stage DEUTZ and WEYHAUSEN demonstrated at bauma a so-called “mild” hybrid system with a motor-generator being installed in the power train between diesel engine and hydraulic pump. Such systems allow fuel savings between 10 and 20 percent.
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