Work

Maximizing Efficiency in a Retrofitted Battery-Powered Material Handler by Novel Control Strategies

Year: 2025

Type: article

Abstract: The electrification of non-road mobile machinery is advancing to enhance sustainability and reduce emissions. This study investigates how to maximize the efficiency of the retrofitting of a material handler from an internal combustion engine to a battery-powered electric motor, while keeping the hydraulic system unchanged. Using a previously validated model, this study proposes three control strategies for the electric motor and hydraulic pump to enhance efficiency and performance. The first control strategy optimizes hydraulic pump performance within its most efficient displacement range. The second strategy maximizes powertrain efficiency by considering both efficiencies of the electric motor and hydraulic pump. The third strategy uses a servo-actuated valve to adjust the load-sensing margin and exhibits energy savings up to 14.2% and an 11.5% increase in efficiency. The proposed strategies avoid complex optimization algorithms, ensuring practical applicability for small- and medium-sized enterprises, which often face cost constraints and limited scalability.

Source: Actuators

DOI: 10.3390/act14110553

Authors: Marco Ferrari, Daniele Beltrami, Vinay Partap Singh, Tatiana Minav, Stefano Uberti

Institutions: University of Brescia, Tampere University, University of Tampere

Language: English

Topic: Electric and Hybrid Vehicle Technologies

Subfield: Automotive Engineering

Field: Engineering

Domain: Physical Sciences

SDGs: Industry, innovation and infrastructure, Affordable and clean energy

Open Access status: gold

Estimated APC paid: $2,896