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Slide1
Team 4Senior Design Final PresentationMay 7, 2011
Slide2Liz Kladder Jay Prins Zach Talen Tim Bangma Jon Mulder
Slide3Outline
Project Introduction
Hybrid Technologies
Our Hydraulic System
Prototyping
Testing
Results
Business Plan
Conclusions
Slide4Project Introduction
Context
Efficient energy usage
Problem
Inefficient vehicle use can be unavoidable in some applications
Solution
Improve efficiency with the
hydraulic
h
ybrid
s
ystem
Slide5Overall Project Goal
Validate Hydraulic Hybrid System can increase stop and go fuel efficiency by 40%
Slide6Design Norms
Stewardship
Caring
Transparency
Slide7Hybrid Technologies
ElectricToyota PriusFlywheelFormula 1HydraulicUPS
Slide8Benefits of a Hybrid System
Regenerative brakingOptimal engine performanceDecreased brake maintenance
Slide9Benefit of Hydraulic Hybrids
Less energy conversionsElectricHydraulic
Slide10Two Types of Systems
www.Eaton.com
Series
Parallel
Slide11Hydraulic System
Slide12Hydraulic System: Accelerating
Slide13Hydraulic System: Coasting
Slide14Hydraulic System: Braking
Slide15Prototypes
Base CaseHydraulic Hybrid
Slide16Base Case Cart:
Frame
Slide17Base Case Cart: Gas Engine Mounting
Slide18Base Case Cart: Drive Train
Slide19Hydraulic Hybrid Cart
Removed base case drive train
Retrofitted cart with hydraulic components
Hydraulic Pump
Hydraulic Motor
Accumulators
Reservoir
Hydraulic Valves
Slide20Hydraulic Hybrid Cart
Slide21Reservoir
Slide22Hydraulic Pump
Slide23Accumulators
Slide24Flow Control Valves
Slide25Hydraulic Motor
(www.grainger.com)
Slide26Other Components
Redundant Brakes
Hydraulic
Mechanical
Linkages
Gas pedal
Brake pedal
Slide27Hydraulic Hybrid Retrofit Costs
Component
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
Slide28Test Procedure
Slide29Testing Video
Slide30Results
Base Case CartHydraulic Hybrid CartStop and Go Fuel Economy13.9 mpg21.1 mpg
52.4%
increase in average stop and go fuel economy
Slide31Improvements
Different pump or hydraulic motor
Variable displacement motor
Check valves with lower cracking pressure
Design to eliminate minor losses
Slide32Business Plan
Target MarketPackage delivery, garbage trucks, city busesIntroduction to the marketO.E.M.Retrofit is to expensivePotential SavingsHigher gas mileage, lower maintenance costs
Slide33Business Plan
FeasibilityHigh cost on prototypePay back period is 19 years at current gas prices ($4.20)Longer than the life of the vehicle
Slide34Obstacles
Budget
Time
Experience with Hydraulic Systems
Component Failure
Slide35Slide36Conclusions
Met our goal!
Met efficiency expectations
Proved our system works
Very expensive system
Learned a lot
Had fun!
Slide37Acknowledgements
Matt Mills & Kelly
Dawley
– Vermeer Corporation
Vermeer Charitable Foundation – Financial Support
Ned Nielsen – Team Advisor
Ren
Tubergen
– Industrial Consultant
Phil
Jasperse
– Calvin College Metal Shop
Charlie Huizinga – Calvin College Physical Plant
Bond
Fluidaire
, Inc – Hydraulic hose and fittings
Great Lakes Fluid Power – Accumulator Charging
Rex
Sheler
– Decals
Mike Harris – Donor Acquisition
Jim
Kuipers
– Cart Donation
Family and Friends
Slide38Questions?
Team 4
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