Team 4Senior Design Final Presentation

May 7, 2011

Liz Kladder Jay Prins Zach Talen Tim Bangma Jon Mulder

OutlineProject IntroductionHybrid TechnologiesOur Hydraulic SystemPrototypingTestingResultsBusiness PlanConclusions

Project IntroductionContext Efficient energy usage

Problem Inefficient vehicle use can be unavoidable in some applications

Solution Improve efficiency with the hydraulic hybrid system

Overall Project GoalValidate Hydraulic Hybrid System can increase

stop and go fuel efficiency by 40%

Design Norms

Stewardship

CaringTransparency

Hybrid TechnologiesElectric

Toyota Prius

FlywheelFormula 1

HydraulicUPS

Benefits of a Hybrid SystemRegenerative brakingOptimal engine performanceDecreased brake maintenance

1800 2300 2800 330013.213.413.613.814.014.214.414.614.8

Power per Fuel Flow Rate vs Engine rpm

Engine Speed [rpm]

Pow

er

per

Fuel

Flo

w [

hp/

(gal/

hr)

]

Benefit of Hydraulic HybridsLess energy conversions

Electric

Hydraulic

Two Types of Systems

www.Eaton.com

Series

Parallel

Hydraulic System

Hydraulic System: Accelerating

Hydraulic System: Coasting

Hydraulic System: Braking

PrototypesBase CaseHydraulic Hybrid

Base Case Cart: Frame

Base Case Cart: Gas Engine Mounting

Base Case Cart: Drive Train

Hydraulic Hybrid CartRemoved base case drive trainRetrofitted cart with hydraulic components

Hydraulic PumpHydraulic MotorAccumulatorsReservoirHydraulic Valves

Hydraulic Hybrid Cart

Reservoir

Hydraulic Pump

Accumulators

Flow Control Valves

Hydraulic Motor

(www.grainger.com)

Other ComponentsRedundant Brakes

HydraulicMechanical

LinkagesGas pedalBrake pedal

Hydraulic Hybrid Retrofit CostsComponent Cost

Eaton Hydraulic Pump $246.50

Accumulators Inc. Accumulators $3286.00

7 gal. Reservoir $100.00

Haldex Hydraulic Motor $200.25

Misc. Hydraulic Valves $843.00

Misc. Hoses and Fittings $550.00

Mechanical Couplers $60.00

Pressure Fixtures $1000.00

Total $6285.75

Test Procedure

Testing Video

ResultsBase Case Cart

Hydraulic Hybrid Cart

Stop and Go Fuel Economy

13.9 mpg 21.1 mpg

52.4% increase in average stop and go fuel economy

ImprovementsDifferent pump or hydraulic motor

Variable displacement motorCheck valves with lower cracking pressureDesign to eliminate minor losses

Business PlanTarget Market

Package delivery, garbage trucks, city busesIntroduction to the market

O.E.M.Retrofit is to expensive

Potential SavingsHigher gas mileage, lower maintenance costs

Business PlanFeasibility

High cost on prototypePay back period is 19 years at current gas

prices ($4.20) Longer than the life of the vehicle

$0.00 $10.00 $20.00 $30.00 $40.00 $50.00 $60.000

5

10

15

20

25

Vehicle Payback Based on Gas Price

Gas Price per Gallon ($)

Lif

eti

me o

f V

ehic

le (

years

)

ObstaclesBudgetTimeExperience with Hydraulic SystemsComponent Failure

ConclusionsMet our goal!

Met efficiency expectationsProved our system works

Very expensive systemLearned a lotHad fun!

AcknowledgementsMatt Mills & Kelly Dawley – Vermeer CorporationVermeer Charitable Foundation – Financial SupportNed Nielsen – Team AdvisorRen Tubergen – Industrial ConsultantPhil Jasperse – Calvin College Metal ShopCharlie Huizinga – Calvin College Physical PlantBond Fluidaire, Inc – Hydraulic hose and fittingsGreat Lakes Fluid Power – Accumulator ChargingRex Sheler – DecalsMike Harris – Donor AcquisitionJim Kuipers – Cart DonationFamily and Friends

Questions?