Off-highway vehicles manufacturers have now to face an increasing demand of high performances while reducing fuel consumption and pollutant emissions. Innovation is the answer, leading to the implementation of new technologies and methodologies for product design. In this context, mechatronic system simulation is certainly a precious ally to support not only component design and optimization, but also subsystem integration and architecture choices. The aim of the paper is to demonstrate the interest of system simulation at vehicle level to design energy recovery systems and estimate the benefits in term of energy consumption in the context of a full vehicle. The results obtained with the excavator simulation model are comparable to those announced by the manufacturers' field; in terms of fuel savings (21.5% versus 25%) and mechanical power reduced (a 20% reduction may be assumed). The numerical model presented in this paper allows estimating the benefit in term of energy consumption of two energy recovery systems, as well as the impact on the performance/operability of the equipment. These numerical models can be used to assed the following scenarios: simulate other working cycles; simulate the integration of a downsize combustion engine; simulate the impact of additional loads... Extensions of these simulators are under-development: simulate the close coupling between the engine, its control and the system to assess in details transient manoeuvres (requires an enhancement of the engine model by mean of a Mean Value model for the combustion and the detailed air path representation); simulate more accurately the accumulators (with real gas assumption and thermal exchanges) to be more predictive on the quantity of energy stored.


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