Project Report: Application of Hydraulic Hybrid System Analysis

This report details a mechanical engineering project focused on enhancing fuel efficiency through the application of a hydraulic hybrid system. The project involved researching various hybrid methods, designing a prototype, and conducting tests to evaluate the system's performance. The primary objective was to improve fuel efficiency, with a secondary goal of maintaining performance consistency compared to non-hybrid vehicles. The project encompassed research on hybrid technologies, designing a base case vehicle, creating schematic diagrams, and preparing presentations. The student, a mechanical engineering team member, utilized their skills in testing, documentation, and system design. The project explored the use of an accumulator, regenerative braking, and various control mechanisms. The report highlights the identified issues, such as budget constraints, and the solutions implemented, including the use of manual control systems and analog gauges. The project successfully achieved a 52% fuel efficiency, demonstrating the potential of hydraulic hybrid technology. The report concludes with an overview of the project's contributions, achievements, and the student's enhanced technical competencies.

CAREER EPISODE 1
CE 1.1 Project Information
Name of the project: Application of Hydraulic Hybrid System to increase fuel
efficiency
Location of the project: [please fill name of the place where the project was conducted]
Project Duration: From [please fill] to [please fill]
Organization: [please fill]
Role and Designation during the time: Project Team Member
CE 1.2 Project Background
CE 1.2.1 Characteristics of the project
This project was undertaken for increasing the fuel efficiency in a vehicle by using a
hydraulic hybrid system. Research on various hybrid methods is necessary with the increase in
demand for better fuel on vehicles. Inefficient usage of fuel cannot be avoided in case of many
vehicles. This project was undertaken to provide a resourceful solution to the issue of inefficient
usage of fuel and increase in fuel prices. My project team members investigated a hydraulic
hybrid system for resolving the issue of inefficient fuel usage. This project focused on testing the
hybrid technology.
CE 1.2.2 Aim and Objectives developed for the project
The main objective of this project was to make sure that a hydraulic system based on
hybrid technology could enhance the stop-and-go efficiency of fuel by 40 percent. One of the

Project Supervisor
Team Member Team MemberTeam Member
(ME)
Project Team Leader
primary objectives was to test the hydraulic system by designing a prototype of the system. The
secondary objective was to maintain a performance consistency between the hybrid vehicle and a
non-hybrid vehicle. These objectives also included adequate acceleration, taking necessary safety
precautions and adequate braking capabilities.
CE 1.2.3 My area of work
I was one of the project team members. My team leader had distributed the
responsibilities among all the members based on our talents and qualifications. I was given a
significant role while working on this project. I had to carry out a relevant research study for
getting an insight into various types of hybrid vehicles and advantages of a hydraulic hybrid
system. I had to assist the team leader in determining a value of baseline of the fuel efficiency. I
also had to design a base case vehicle or cart. My main area of work was to research and carry
out the documentation process. I also had to make the schematic diagrams and prepare a
presentation for demonstrating the entire project work.
CE 1.2.4 Project Group

Figure 1: People involved in the project
CE 1.2.5 My responsibilities throughout the project
Being a mechanical engineer, my main responsibility was to test the hydraulic system by
designing a prototype of the system. I was responsible for correctly testing the base case vehicle
or cart. I had to make sure that safety precautions were considered while working on this project.
I had to conduct appropriate tests for determining the advantages of a hydraulic hybrid vehicle or
system. I was responsible for preparing the project schedule and ensuring completion of project
activities as per the schedule of the project. The team leader had also assigned me the task to
plan the project budget based on prototype cost and bill of materials. I had to make sure that the
research studies and test results were properly documented.
CE 1.3 Distinctive Activity
CE 1.3.1 Comprehending the theory of the project
A hybrid vehicle operates by using a secondary device for storing energy and a primary
engine. Hybrid vehicles with hydraulic technology are gaining importance with time and are
considered to be a better option as compared to hybrid vehicles with electronic components.
There are two types of hydraulic systems: series and parallel hybrid systems. Hydraulic hybrids
offer several benefits such as regenerative braking, optimal speed of engine and less energy
conversions that lead to higher efficiency.

Figure 2: Basic Structure of Hydraulic Hybrid Vehicle
The accumulator is the most significant part of the hydraulic system. For data logging
and calibration, a software tools is used that runs when actual controller can actively monitor the
incoming data and thus alter the output value. A plot of data while an experiment is given below:

Figure 3: Graph for data plot collected from charging and discharging the Accumulator
CE 1.3.2 Engineering knowledge and skills applied in the project
I have utilized my knowledge of hybrid technology and different types of hybrid vehicles
for executing the project activities. My mechanical engineering skills and knowledge were used
for designing the prototype of the system. I utilized my technical skills for modifying the frame
of the base case vehicle or cart. I applied my hydraulic vehicle control knowledge to control the
acceleration by carrying out proper adjustment of the throttle and through the use of one
restrictive control valve. I have utilized my mechanical engineering skills for carrying out engine
mounting, accumulator mounting and reservoir mounting of the hydraulic hybrid system. I was
able to use my testing knowledge for appropriately testing the hybrid system.
CE 1.3.3 Accomplishment and task performed
The project was completed within a specified time and according to the project schedule.
The technical competencies of my project team and proper planning led to the success of the
project. This project helped me to gain immense knowledge about the hydraulic systems through
a systematic research study and practical work. I was able to assist my team members to achieve
52 percent fuel efficiency. After the completion of research work, I created a schematic of the
hydraulic system. The schematic included braking control and acceleration by using hydraulic
control valves. The regenerative braking was used by using a check valve. I also made use of
directional selector valves for reverse and forward directions. A high-pressure relief valve was
used for ensuring safety of the system. I was successful in determining the baseline value for
comparing the performance and effectiveness of the hybrid system. I had carried out a driving
test of the base cart before as well as after the retrofitting of the hydraulic components. I carried
out three types of tests: city driving, mid-level speed and top speed tests. Presence of technical

difficulties did not allow the completion of the test, but the objective of the project of enhancing
fuel efficiency was achieved.
The hybrid hydro-mechanical drive is the method for controlling the torque at every
wheel.
Figure 4: Hybrid Hydro-Mechanical Drive
CE 1.3.4 Identified issues and their solutions
1.3.4.1 Issues
The budget constraint was the main issue in this project. The other team members did not
have strong knowledge regarding hydraulic systems and hybrid technology. They were facing
issue while working on this project.
1.3.4.2 Solutions
I decided to use a manual control system of the engine instead of an automated regulation
system for overcoming the budget limitation. Due to the constraint of budget, I suggested my
project team members to use analogue gauges instead of digital gauges which were expensive in
nature. To enhance the knowledge of hydraulic system and hybrid technology of the other team
members, I carried out an intensive research work and demonstrated the findings in a PowerPoint

presentation. This process helped the team members to get a better understanding of the project
requirements and objectives. I assisted them throughout the entire project for resolving their
issues and problems.
CE 1.3.5 Plan to produce creative and innovative work
Initially, I had decided to utilize electronic components for monitoring the pressure of the
accumulator and controlling a stepper motor for varying the throttle. Later on, I realised that use
if electronics will not be feasible due to the lack of complex design knowledge and high cost of
the electronic sensor. There were other disadvantages such as debugging complexity and
different modes of system failure. Therefore, I decided to use mechanical means such as the use
of hydraulic cylinders for controlling the throttle of the engine. I chose hydraulic cylinders
because this can allow for the variation in the position of the piston. I used a restrictive flow
valve for controlling the acceleration as well as the braking of the hybrid vehicle. I had placed
this control valve between the hydraulic motor and the high-pressure manifold for keeping the
acceleration under control. I assisted my team members in deciding and choosing the high-
pressure relief valve for ensuring safety of the passenger, driver as well as the hydraulic
components.
CE 1.3.6 Collaborative work
I clarified all the doubts of the team members and helped them in executing the project
activities according to the project schedule. My team leader was supportive and guided us
throughout the entire project work. I maintained harmony among the team members and resolved
any conflict that occurred.

CE 1.4 Project Review
CE 1.4.1 Project Overview
This project was about enhancing the fuel efficiency in a vehicle by utilizing the
functionalities of a hybrid system based on hydraulic technology. This project provided a
resourceful solution to the problem of inefficient use of fuel. This project aimed at increasing the
fuel efficiency by 40 percent. I was able to achieve 52 percent fuel efficiency by applying my
mechanical engineering, designing and testing skills.
CE 1.4.2 My contribution to work
I made significant contributions to the success of the project. The intensive research study
carried out by me helped in executing the project activities in an appropriate manner. I had
effectively used MS project to create the Gantt chart for preparing the project schedule. I was
able to deliver an accurate budget plan by considering all the constraints. I maintained
professional conduct throughout the project and promoted coordination among the team
members. I was successful in accurately preparing the project reports and technical documents.
My presentation as well as technical skills had impressed the project supervisor. I could solve
complex engineering problems by using my engineering skills and knowledge. This project
helped me to enhance my technical competencies.