Energy-saving recovery technologies in hydraulic systems of construction cranes with variable boom geometry

Abstract

Modern construction cranes with variable boom geometry are characterized by high energy consumption of hydraulic systems, which is due to significant energy losses during throttle control and the lack of efficient recovery systems. The present study is aimed at the development and experimental evaluation of energy-saving recovery technologies for hydraulic systems of construction cranes. The study was conducted using an integrated approach, including mathematical modeling of hydraulic processes, experimental tests on a specialized stand, and an analysis of the effectiveness of various energy recovery systems. The experimental base included a laboratory stand with a three-link crane of variable geometry and hydraulic, electric and combined recovery systems. The results showed that the use of a combined heat recovery system provides an increase in energy efficiency by 34-39% compared to traditional hydraulic systems. The coefficient of potential energy recovery when lowering the boom reaches 0.41, which is 23% higher than in hydraulic accumulator systems. The energy density of the combined systems is $1.8-2.2~MJ/m3$, which is 1.6 times higher than traditional hydraulic accumulators. The theoretical significance of the study lies in the development of methodological foundations for the design of energy-efficient hydraulic systems for mobile cranes, and the practical value is determined by the possibility of reducing operating costs by 15-20% and reducing $CO_{2}$ emissions by 25-30%. The prospects for further research are related to the optimization of control algorithms for regenerative systems and the integration of machine learning technologies for predicting energy consumption.