Parameter Matching Optimization of Electro-hydraulic Compound Drive Swing System for High Efficiency

doi:10.3901/JME.260547

Abstract

Abstract: The traditional excavator swing system, driven by hydraulics, suffers from high energy consumption and limited control performance. Although electrification is a widely adopted solution, a pure electric drive configuration tends to cause significant vehicle impact and performs poorly under high-torque stall conditions such as sidewall excavation. In this study, the working principle, typical operating conditions, and main energy consumption patterns of the excavator swing drive system are analyzed. Based on this analysis, an electro-hydraulic composite drive swing system is proposed, which integrates the high energy efficiency and good maneuverability of electric drives with the high power density and strong holding capability of hydraulic drives. The swing system is driven by a combination of a permanent magnet synchronous motor and a four-quadrant pump, and the kinetic energy generated during rotational braking is recovered through an accumulator and a power battery. To fully exploit the advantages of the electro-hydraulic composite system, energy efficiency is adopted as the performance evaluation metric. Taking an 8-ton electric hydraulic excavator as an example, the parameters of the key components are optimized. Traditional parameter matching often considers single-variable problems and is conducted offline, making it difficult to address complex and dynamic multi-objective optimization. Therefore, a dynamic programming algorithm is employed for energy efficiency optimization of the electro-hydraulic drive system, and a genetic algorithm is used for matching and optimizing the parameters of the main components at each sub-stage, with system economy as the objective. Experiments are carried out to validate the rationality of the designed parameters. The results show that the proposed system achieves a 2% improvement in energy recovery rate. Compared with the electric drive swing system and the traditional hydraulic swing system, the energy-saving rate of the electro-hydraulic composite drive system is improved by 54.5% and 72.5%, respectively.

Key words: electric excavator, electro-hydraulic compound, swing system, parameter matching, energy efficiency

CLC Number:

TG156

FU Shengjie, WU Dijian, REN Haoling, CHEN Qihuai, LIN Tianliang, YAO Zhaoyuan, HU Tian, ZHENG Weijie. Parameter Matching Optimization of Electro-hydraulic Compound Drive Swing System for High Efficiency[J]. Journal of Mechanical Engineering, 2026, 62(14): 391-401,414.

Add to citation manager EndNote|Reference Manager|ProCite|BibTeX|RefWorks

URL: http://www.cjmenet.com.cn/EN/10.3901/JME.260547

http://www.cjmenet.com.cn/EN/Y2026/V62/I14/391

References

[1] NG F，HARDING J A，GLASS J. An eco-approach to optimise efficiency and productivity of a hydraulic excavator[J]. Journal of Cleaner Production，2016，112：3966-3976.
[2] 杨宁，李冰，徐武彬，等. 工程机械节能减排现状及发展新趋势[J]. 机械设计与制造，2021(1)：297-300，304. YANG Ning，LI Bing，XU Wubin，et al. Current situation and new development trend of energy conservation and emission reduction for construction machinery[J]. Machinery Design & Manufacture，2021(1)：297-300，304.
[3] DO T C，DANG T D，DINH T Q，et al. Developments in energy regeneration technologies for hydraulic excavators：A review[J]. Renewable and Sustainable Energy Reviews，2021，145：111076.
[4] HUANG Xiaohui，YAN Wanbin，CAO Huajun，et al. Prospects for purely electric construction machinery：Mechanical components，control strategies and typical machines[J]. Automation in Construction，2024，164：105477.
[5] 林元正，林添良，陈其怀，等. 电动工程机械关键技术研究进展[J]. 液压与气动，2021，45(12)：1-12. LIN Yuanzheng，LIN Tianliang，CHEN Qihuai，et al. Research progress on key technologies of electric construction machinery[J]. Chinese Hydraulics & Pneumatics，2021，45(12)：1-12.
[6] FASSBENDER D，ZAKHAROV V，MINAV T. Utilization of electric prime movers in hydraulic Heavy-duty-mobile-machine implement systems[J]. Automation in Construction，2021，132：103964.
[7] MU Hongyun，CHENG Min，TANG Xiongfeng，et al. A hybrid distributed-centralized load sensing system for efficiency improvement of electrified construction machinery[J]. Energy，2025，314：134123.
[8] JUNG T，RADUENZ H，KRUS P，et al. Boom energy recuperation system and control strategy for hydraulic hybrid excavators[J]. Automation in Construction，2022，135：104046.
[9] GONG Jun，ZHANG Daqing，GUO Yong，et al. Power control strategy and performance evaluation of a novel electro-hydraulic energy-saving system[J]. Applied Energy，2019，233-234：724-734.
[10] LIN Tianliang，WANG Lang，HUANG Weiping，et al. Performance analysis of an automatic idle speed control system with a hydraulic accumulator for pure electric construction machinery[J]. Automation in Construction，2017，84：184-194.
[11] CHEN Qihuai，LIN Tianliang，REN Haoling. Parameters optimization and control strategy of power train systems in hybrid hydraulic excavators[J]. Mechatronics，2018，56：16-25.
[12] NGUYEN V H，DO T C，AHN K K. Hybrid powertrain with dual energy regeneration for boom cylinder movement in a hydraulic excavator[J]. Automation in Construction，2025，171：105974.
[13] GE Lei，QUAN Long，ZHANG Xiaogang，et al. Efficiency improvement and evaluation of electric hydraulic excavator with speed and displacement variable pump[J]. Energy Conversion and Management，2017，150：62-71.
[14] QIN Tao，MA Yuxiang，LI Yunhua，et al. Torque equilibrium position closed-loop control of dual electric motors swing system for large mining excavator[J]. Mechatronics，2023，95：103035.
[15] YAO Hong，WANG Qingfeng. Control strategy for hybrid excavator swing system driven by electric motor[J]. IFAC Proceedings Volumes，2013，46(5)：109-115.
[16] WANG Xiangyu， GE Lei， LI Yunhua， et al. Research on energy efficiency characteristics of mining shovel hoisting and slewing system driven by hydraulic-electric hybrid system[J]. Chinese Journal of Mechanical Engineering， 2023， 36(6)： 209-223.
[17] QIN Tao， QUAN Long， LI Yunhua， et al. A dual-power coordinated control for swing system of hydraulic-electric hybrid excavator[C]. 2021 IEEE/ASME International Conference on Advanced Intelligent Mechatronics (AIM)， 2021： 55-60.
[18] GE Lei， DONG Zhixin， QUAN Long， et al. Potential energy regeneration method and its engineering applications in large-scale excavators[J]. Energy Conversion and Management， 2019， 195： 1309-1318.
[19] CASOLI P， GAMBAROTTA A， POMPIINI N， et al. Hybridization methodology based on DP algorithm for hydraulic mobile machinery—Application to a middle size excavator[J]. Automation in Construction， 2016， 61： 42-57.
[20] YI Lixin， ZHU Jianxin， SHEN Chao， et al. Research on parameter optimization matching of slewing energy saving of hydraulic hybrid excavator[J]. Arabian Journal for Science and Engineering， 2024， 50(12)： 9449-9464.
[21] 马永杰，云文霞. 遗传算法研究进展[J]. 计算机应用研究， 2012， 29(4)： 1201-1206， 1210. MA Yongjie， YUN Wenxia. Research progress of genetic algorithm[J]. Application Research of Computers， 2012， 29(4)： 1201-1206， 1210.
[22] 葛继科，邱玉辉，吴春明，等. 遗传算法研究综述[J]. 计算机应用研究， 2008(10)： 2911-2916. GE Jike， QIU Yuhui， WU Chunming， et al. Summary of genetic algorithms research[J]. Application Research of Computers， 2008， 25(10)： 2911-2916.
[23] 陈洁，杨秀，朱兰，等. 微网多目标经济调度优化[J]. 中国电机工程学报， 2013， 33(19)： 57-66， 19. CHEN Jie， YANG Xiu， ZHU Lan， et al. Multi-objective economic dispatch optimization of microgrid[J]. Proceedings of the CSEE， 2013， 33(19)： 57-66， 19.