CONTENTS

1.
2.
3.
4.

ABSTRACT
LIST OF SYMBOLS
INTRODUCTION
HYDRAULIC DRIVES IN OFF-THE-ROAD
VEHICLE
5. EXPERIMENTAL SET UP
6. CONCLUSION
7. ACKNOWLEDGMENTS
8. REFERENCES

ABSTRACT
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Hydrostatic transmission (HST) system used in heavy earth moving machineries

(HEMMs) has high power density, wide range of speed control and good overall
efficiency. Hydrostatically coupled two motor summation drive is an alternative
power transmission system, compared to existing closed-loop HST system with
low speed high torque motor, used in HEMM. Such drive arrangement has made
the possibility to design the transmission system, used in heavy vehicles, in an
efficient way to cover wide range of torque-speed demand. This article studies the
concept of two motor summation drive and its steady state performance.
Experiments have been carried out to analyze the performance of such system. The
characteristics of single and two motor drive systems are compared at different
load-torque and speed levels. It is concluded that two motor hydrostatic drive
systems is more effective at high load-torque and low speed compared to single
motor drive system.

Keywords:
Hydrostatic transmission (HST),Two motor summation drive , Theoretical range
(TR) ,Steady-state performance , Heavy earth moving machinery (HEMM)

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Seminar Guide

Seminar In-Charge

LIST OF SYMBOLS
Dp

Displacement of the main pump

Dm General displacement of the hydro-motor

Dm1 Displacement of the hydro-motor-1
Dm2 Displacement of the hydro-motor-2
DPp Differential pressure across the main pump
Qp

Flow supplied by the main pump

Tl

Generalized load-torque

Tld

Load-torque on double motor

Tls

Load-torque on single motor

am1 Displacement setting of the hydro-motor-1

am2 Displacement setting of the hydro-motor-2
ap

Displacement setting of the main pump

gd

Efficiency of the two motor drive system

gs

Efficiency of the single motor drive system

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HOD(ME)

Generalized speed of HST drive

xm1 Speed of the hydro-motor-1

xm2 Speed of the hydro-motor-2

INTRODUCTION:
In a hydrostatic transmission (HST) system, the mechanical energy of the input
drive shaft of the pump is converted to pressure energy in a nearly compressible
working fluid and then reconverted into mechanical energy at the output of the
drive shaft of the motor. It is used to transmit the rotational mechanical power from
one source to another without the use of gears. It provides much softer power
transmission than mechanical gear train. High power density, wide speed range of
speed control and good overall efficiency are important demands of a modern HST
system intended to be used in a heavy off-road vehicles. A systematic overview on
mobile hydraulics from industry perspective is presented by Eckhardet al. With
regard to the overall reduction of fuel consumption of the vehicle, Ossyra has
presented a comprehensive control strategy of hydrostatic drive used in mobile
vehicles. A different hydrostatic driveline concept for off-highway machines
through system modeling and simulation with a wheel loader as an example is
made by Torsten. In such investigation, simulation tool has been developed to
analyze the performance of the drivelines regarding losses in every component of
the transmitting system. Carl et al has made a detailed study to apply power split in
vehicle drive trains. They have investigated four architectures of power split
transmission illustrating the advantages and disadvantages of each type with regard
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to energy consumption, efficiency, system complexity, compactness and control

effort for off-road vehicles. Most vehicles require high tractive forces during
starting and climbing that may be 1030 times the relatively light load in normal
operation. Vehicle speed and load vary over a wide range and require a maximum
tractive effort when starting under full load. Hydraulic systems using fixed
displacement pump are inefficient in cases where the desired velocity and load
vary over a wide range, since the excess flow is dissipated over a relief valve The
maximum performance of the hydrostatic drive depends on the functioning of its
components that mainly depends on various operating conditions. While the
longterm hydrostatic components development focuses on achieving small gains
by improving efficiency, it is to be focused to maximize the system efficiency by
creative system engineering with standard components. Two motor summation
drive system is one of the creative system engineering. Concepts based on using
more than one motor offer other advantages for cases where high power must be
transferred through the transmission. The obvious way is to connect the motors in
parallel and to control them in parallel. Another way is to control them in
sequence. In such a concept, one or two hydro-motors are powered hydraulically
and connected with the load, depending on the loading conditions or the gradient
of tracks. Various authors have studied the connection and disconnection
procedures to be adopted for its fast, smooth and stable operation has tested a
summation drive using hardware-in-the-loop simulation (HWIL). It shows that the
connection using active control of the zero-motor works best at high load
condition. Very few literature is available regarding the performance investigation
on multi-motor hydrostatic drive system.This article compares the steady state
performance of single motor and two motor closed-loop HST systems used in the
off-the-road vehicle.

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Typical traction speed characteristics for a wheel loader

Hydraulic Drives in Off-the-Road Vehicle In hydrostatic drive systems, either by

allowing the displacement of the pump and the motor or by controlling the flow
rate supplied from the pump through proportional valve to the motor, the
transmission characteristics are varied. Maximum speed and maximum tractive
effort are usually not required to occur simultaneously in a machine. Generally, it
is accepted for a construction machine to slow down when output torque
requirement goes up and vice versa. The use of variable displacement pump and
motor meets this requirement. Such drive concept is currently the state of the art in
the wheel loader.HEMMs are subjected to extremely variable loading conditions
and hence there is a need for sophisticated control for improved performance. To
cater

the

requirement

of

wider

torque-speed

demand

with

maximum

performance,high velocity range of the mobile machineries is state of the art in the
wheel loader.HEMMs are subjected to extremely variable loading conditions and
hence there is a need for sophisticated control for improved performance. To cater
the requirement of wider torque-speed demand with maximum performance,High
velocity range of the mobile machineries is required. This demand is quantified by
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Theoretical Range (TR), which is the ratio of highest vehicle speed to lowest speed
at maximum engine power. Increase in TR value fulfills the required demand of the
mobile machineries.A traditional solution for an HEMM is to use a hydrodynamic
transmission system (torque converter) in series with multi-speed gear box.
However, due to limited number of speed stages in an additional gear box, used in
hydrodynamic system, an HST system may be used as an alternative drive
arrangement of HEMM. The characteristics of the drive systems used in HEMM.
In an HST system with the single motor drive, the increase in the load-torque
increases the system pressure that affects the efficiencies of the hydrostatic
components and the overall system. Therefore, these drives will be effective within
a limited range of the TR value. To use such drive for higher TR value with
reasonable efficiency, it is connected with multi-speed gear unit. However, main
using a single larger one. During high load demand, both hydro-motors are used
and develop maximum torque at their maximum displacement. For high speed and
low load operation, one hydro-motor strokes to zero displacement to improve
efficiencies.This article studies the steady state performance of two motor
summation drive both theoretically and experimentally. In this respect, a system
has been designed and fabricated the schematic representation of which is shown
in The performance of the system has been compared with the drive using single
motor transmission system.

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EXPERIMENTAL SET UP:

Description of the Test Set Up A schematic hydraulic circuit diagram of the two
motor summation drive considered in the present analysis.

Simplified representation of the experimental test set up

TABLE.1,LIST OF MAJOR COMPONENTS USED IN THE TEST SET UP:
S/No: Item description:
1. Electric motor (15 kW)
2. Main pump unit 9. Flushing block
3. 3/2 Directional control valve (DCV)
4. High pressure relief valve (4.14.4)
5. Bent axis motor
6. Gear box (Gear ratio 1:1)
7. Loading pump unit
8. Pressure relief valve (PRV) at loading
10. Booster pump
11. Flow control valve
12. Pressure sensor (12.112.6)
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13. Speed sensor

List of major components and their specifications are given in Table 1 and 2
respectively. The photographic view of the test set up is shown in Fig. 5. The
operation of two motor summation drive is shown in Fig. 4.A 15 kW electric motor
(1) rotating at 1,450 rpm drives the main pump (2), the swash plate angle of which
is varied by the command signal sent from the control panel. Thus the flow
supplied by the pump to the bent axis motors (5.1and 5.2) is varied. The motors
drive the loading pump (7) through the gear unit (6). The displacement of the pump
(7) is varied by the command signal sent from the control panel. The pump (7)
supplies flow through the pressure relief valve (8). The load on the hydro-motor is
varied by adjusting the pressure setting of the relief valve.The experiments were
conducted for the following two conditions:
TABLE 2, SUMMARY OF MAJOR COMPONENTS AND INSTRUMENTS
USED IN TEST SET-UP:
Item no: Name of the component and Summary of specification
2 and 7 Axial piston variable displacement pump Displacement 28 cc/rev Nominal
Pressure 400 bar.
5.1 and5.2 Bent axis motor Displacement 16 cm3/rev Nominal pressure 400 bar
4 and 8 High pressure relief valve Max. set pressure 350 barMax. flow 200 LPM
11. Flow control valve or sensor Max. range 60 LPM Analogue o/p 420mA
Linearity 0.42 %
12. Pressure sensor (12.112.6) Pressure range
12.1 and 12.2 :0150 bar12.312.6 :0200 bar
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13. Non contact type optical speed sensorMax. range 05,000 rpm Accuracy 0.5 %
Driving the single motor:
For driving the single motor,power is supplied to the DCVs (A1and
B1).Experimental Procedure The experiment was conducted at wide range of speed
and torque levels, following a standard procedure. A stable source of power supply
was provided to the electric motor driving the main pump that supplies fluid to the
hydro-motors.The motor speed was varied by controlling the swash plate angle of
the pump.Using suitable sensors and instruments, the speed (x) and the torque of
the hydro-motors (Tl), the differential pressure across the main pump (DPp) and
the flow (Qp) supplied by it were measured.During experiment, the viscosity of the
fluid was kept nearly constant by maintaining its temperature at 50 2 _C.
Experiment was repeated several times to examine repeatability before collecting
the data. Test data were collected at different torque levels by adjusting the set
pressure of the relief valve.
Experimental Observation:
The expression of the TR and the efficiency of two motor summation drive are
derived under Derivation of TR Value for the Set Up and Expression for
Efficiency of Two Motor Summation Drive respectively.
Determination of TR Value:
Maximum speed of single motor, xm1max = 2,450 rpm Pump reaches maximum
input power at hydro-motor speed, xm1N = 130 rpm Therefore,TR xm1max_
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xm1N 2450=130 18:84 Determination of Efficiency From the data obtained

for the single motor and two motor drive systems, the efficiencies of the systems at
different

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load-torque and speed were calculated using Eqs. 8 and 10, respectively. The
performance characteristics are plotted using best fit lines to the data points. The
characteristics of the two motor and single motor drive systems are shown in Fig. 6
and 7, respectively. From Fig. 6, it is observed that the efficiency of the two motor
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transmission system increases with increase in loadtorque and decrease in

speed.However, efficiency of single motor decreases with increase in torque and
speed levels. It is observed that efficiency of single motor is more than two motor
at low torque, whereas, the efficiency of the single motor drive system is
comparatively less than two motor at higher torque levels, shown in Fig. 7.
Comparing Figs. 6 and 7, it may be concluded that at the high torque and low
speed demand, two motor drive system is more efficient than single motor drive
system, whereas for low torque high speed demand, single motor drive system
would be better than two motor system.

Torque-speed characteristics of two-motor drive system

From the above observations, it may be concluded that machine requiring high
fluctuating load demand as in HEMM, by switching between using single motor or

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two motor in the proposed system, the efficiency of the system increases,
throughout its torque-speed range.
Torque versus Speed Curve:
The torque-speed (T-N) curve for single and two motor were plotted at constant
power which is compared with the theoretical T-N curve .From the above study, it
is observed that by combining the single and two motor drive systems, the TR
value of the proposed closed-loop HST system increases.

CONCLUSION:

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The concept of closed-loop HST system using multi-motor drive has been
discussed and its steady state performance is analyzed. The TR value of the tractive
effort versus speed of the proposed hydrostatic transmission system has been
calculated theoretically and validated experimentally.
From the above study, following conclusions are drawn:
The efficiency of the two motor drive system decreases with increase of speed.
However, the efficiency of this system increases with increase in torque levels.
The efficiency of the single motor drive system decreases with increase in speed
as well as load-torque.
The proposed two motor drive system is an alternative drive arrangement,
compared to the conventional closed-loop HST system with low speed high torque.
Additionally, the two motor summation drive system can have increased TR value
by switching it to operate as a single motor drive system. To meet the fluctuating
load demand of the HEMM, the clutching and declutching methods for switching
between using single and two motor in the proposed multi-motor drive system
should be done quickly and without causing any significant disturbances. Studies
in this regard require more detailed analysis of the system. However, the study
presented in this article may be useful for initial design of the HST system for an
HEMM, where such a drive is incorporated.

ACKNOWLEDGMENTS:

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The Research and Development Project Grant for 20092012 from University
Grant Commission, Government of India, for carrying out the research work on
this topic is acknowledged. The authors are thankful to the representative of Bosch
Rexroth India, Ltd. for their help in fabricating the Test set up.

REFERENCES:
1. T. Ze-yang, Hydraulic motors and vehicle hydrostatic transmission system of
wheel motor type. Patent No. 4903792, 1990
2. S. Eckhard, G. Gerhard, Mobile hydraulicsan overview, in Proceedings of the
5th International Fluid Power Conference, 2022 March, 2006, Aachen, Germany,
vol. 3, pp. 1324
3. J.C. Ossyra, Control Concepts for Vehicle Drive Line to Reduce Fuel
Consumption, VDI Fortschritt-Berichte. Reihe 12 Nr. 598, (VDI, Dusseldorf,
2005), ISBN: 3-18-359812-4
4. K. Torsten, J. Hilman, D. Henning, Comparison of selected fluid technical drive
line concepts for off-highway machines, in 5 th International Fluid Power
Conference, Aachen, Germany, 2006, vol. 3, pp. 4556
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characteristics in power split continuously variable transmissions, in SAE 2006,
Commercial vehicle Congress Exhibition, Oct. 2006, Chicago, IL, USA, SAE
2006-01-3468
6. H.O. Triet Hung, A.H.N. Kyoung Kwan, Modelling and simulation of
hydrostatic transmission system with energy regeneration using hydraulic
accumulator. J. Mech. Sci. Technol. 24(5), 1163 (2012)

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7. M. Sannelius, Hydrostatic Transmissions with Sequence-controlled Motors

Open Control of Zero-motor Connection, Technical report LITH-IKP-R-987 (Dept.
of Mech. Eng., Linkoping University, Linkoping, Sweden, 1997)
8. M. Sannelius, K.O. Palmberg, Control aspects of hydrostatic transmissions with
sequence-controlled motors, in Proceedings, 4th Scandinavian International
Conference on Fluid power, tempere, Finland 1995
9. M. Sannelius, K.O. Palmberg, Hardware in the loop simulation of a hydrostatic
transmission with sequence-controlled motors, in Proceedings, 3rd JHPS
International Symposium on Fluid Power, Yokohama, Japan, 1996
10. M. Sannelius, K.E. Rydberg, Hydrostatic transmissions for wheel loaderscontrol aspects of a multi-motor concept, in International Fluid technisches
Kolloquium, Aachen, Germany, 1996, pp. 389403
11. BS-4617, Methods of Testing Hydraulic Pumps and Motors for
Hydrostatic Power Transmission, 1983, British Standard Institution,
London

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