Hybrid vehicles improve fuel efficiency and reduce harmful emissions. Hybrid Hydraulic Vehicles (HHV) have the potential to double the efficiency of currently available hybrids. To improve the efficiency of hydraulic components used in a HHV, testing needs to be conducted in a laboratory environment.
Testing of hydraulic components determine parameters critical to performance such as speeds, torque, fluid flow, and operating pressures. Efficiency maps are generated. Durability of components is evaluated through endurance testing. Operational limits are established for both components and systems. Simulated operating cycles determine the effects on pump/motor (P/M) and other hydraulic devices in the system. Side effects of operating a hydraulic system such as noise, vibration, and heat are determined. Manufacturer data can be validated and data unavailable from manufacturers can be established. In this thesis, the design and construction of a hydraulic test facility to perform this testing will be detailed. Safety precautions and testing procedures will also be discussed.
The laboratory is capable of testing hydraulic pumps and motors up to 5,000 PSI. Data can be collected on inlet and outlet pressure, inlet and outlet flow rates, fluid temperature, torque, and speed. All test cells can be configured for both pump mode (powered by electric motor) and motor mode (power absorbed by electric dynamometer).