Component sizing and sensitivity analysis of design parameters of a hydraulic-pneumatic regenerative braking system for heavy duty vehicles

• Published in: Energy (Oxford) 2023-02, Vol.264, p.126021, Article 126021
• Main Authors: Bravo, Rafael Rivelino da Silva, Gama, Artur Tozzi de Cantuaria, Oliveira, Amir Antonio Martins, De Negri, Victor Juliano
• Format: Article
• Language: English
• Subjects: Energy efficiency; Hybrid commercial vehicle; Hydraulic hybrid powertrain; Pneumatic hybrid powertrain; Regenerative breaking
• ISSN: 0360-5442
• DOI: 10.1016/j.energy.2022.126021

A regenerative hydraulic-pneumatic braking system for trucks or busses must allow recovery of braking energy in both high energy/low power situations, such as long downhill grades, and low energy/high power situations, such as those typical of urban traffic. Proper component sizing must get the best out of both situations. The main contribution of this work is the development of a component sizing strategy that will greatly accelerate the development of designs for a given target. Once components are defined, subsequent studies can be performed under dynamic conditions to refine the design, including improving local and higher-level controls. The design strategy presented is applied to a 12-ton commercial vehicle and its behavior is then simulated using a full nonlinear dynamic numerical model previously validated against a laboratory prototype. The efficiencies predicted by the design method deviate only by 3.1% and 6.7% from the results of the dynamic model for urban and highway traffic, respectively, which is reasonable for the design phase of a hybrid hydraulic-pneumatic powertrain. The component equations and computational strategy can also be used for sizing other hydraulic or pneumatic system architectures. [Display omitted] •A regenerative hydraulic-pneumatic system for urban and highway transport is proposed.•An analytical model is developed to size the components of the system.•A numerical model is validated using measurements on a prototype.•The equations are applied to size a regenerative system for a 12-ton urban and highway delivery truck.•The performance predicted by the analytical model deviates less than 7% from that of the numerical model.