Energy 153 (2018) 836e848

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Energy
journal homepage: www.elsevier.com/locate/energy

A new type of hydrokinetic accumulator and its simulation in

hydraulic lift with energy recovery system*
Waldemar Latas a, *, Jerzy Stojek b
a
w, Poland
Institute of Applied Mechanics, Cracow University of Technology, Al. Jana Pawła II 37, 31-864, Krako
b
Department of Process Control, AGH University of Science and Technology, Al. A. Mickiewicza 30, 30-059, Krako
w, Poland

a r t i c l e i n f o a b s t r a c t

Article history: The article presents a model and a simulation study of a new type of hydrokinetic accumulator with
Received 24 July 2017 increased energy storage density. The basic elements of the accumulator are: a flywheel of variable
Received in revised form moment of inertia (due to inflow or outflow of hydraulic fluid) and a variable displacement pump/motor.
8 March 2018
The first part of the article describes the construction and operation principles of the developed accu-
Accepted 7 April 2018
Available online 9 April 2018
mulator with three specified work modes. A mathematical model of the presented hydrokinetic accu-
mulator and its simulation in a hydrostatic lift system with energy recovery are given. The results of the
numerical simulations carried out during charging and discharging of the accumulator (i.e. values of the
Keywords:
Hydrokinetic flywheel-accumulator
stored kinetic and potential energy and chosen working parameters) are presented. It is shown that, due
Hydraulic energy storage to energy storage and extraction, in both hydrostatic and rotating kinetic domains, charging and dis-
Energy recovery charging may be decoupled from pressure level. Additionally, the accumulator has the ability to control
Hydraulic hybrid the pressure in the hydraulic system. An example of the control algorithm is also presented in the paper.
Variable displacement pump/motor © 2018 Elsevier Ltd. All rights reserved.
Hydraulic lift

1. Introduction during swings of executing members of devices.

The possibility of recovering and storing energy in modern
machines and devices constitutes an important technological
problem which should be taken into account at the designing stage
as well as during further maintenance. Energy stored in various
forms, e.g. mechanical (flywheel), electrical (batteries), or hydro-
static (hydraulic accumulator) can originate from both mainte-
nance excess and its recovery during device operation. The most
important properties of the stored energy are easiness of its reuse,
total obtainable amount (energy density), and its ability to be
implemented in short intervals of time (power density).
Hydrostatic energy storage is an important problem given its
frequent occurrence in many systems of machines and devices (e.g.
hydrostatic drives of vehicles, hydraulic systems of heavy con-
struction machinery, or systems of presses and lifts). The energy
recovery in these types of applications can occur during vehicle
braking, releasing working elements of machines from loading, or
*
This research did not receive any specific grant from funding agencies in the
public, commercial, or not-for-profit sectors.
* Corresponding author.
E-mail addresses: latas@mech.pk.edu.pl (W. Latas), stojek@imir.agh.edu.pl
(J. Stojek).
Currently, a generally applied component for storing hydrostatic
energy is a hydraulic accumulator which stores potential energy of
a gas, typically nitrogen, compressed by the addition of a hydraulic
fluid (e.g. oil, hydrostatic emulsion) to the chamber. There are three
types of hydraulic accumulators, commonly used in industrial and
mobile applications, which differ in terms of the way in which the
gas is separated from the fluid: by a piston, a bladder, or a dia-
phragm [1,2].
Hydraulic accumulators have an exceptionally broad range of
applications and are basic components supplying means of con-
trolling performance of hydraulic systems. The applications may be
found in: construction machines, mining equipment, agricultural
machinery, machine tools, wind power plants, hydrostatic drives,
forklifts, presses, transportation vehicles, winches, etc. Hydraulic
accumulators can perform the following tasks: compensation for
pressure loss due to leakage, providing support for pump delivery
flow, holding auxiliary power, supplying emergency power, energy
recovery, damping of vibrations, or mechanical shock absorption
[1,2].
The tendency for a continuous improvement of energy effi-
ciency leads to the increased use of hybrid solutions. Hydraulic
accumulators may be components of hybrid drives, serving the
purpose of an additional source of power to the main one, usually a

https://doi.org/10.1016/j.energy.2018.04.040
0360-5442/© 2018 Elsevier Ltd. All rights reserved.
 W. Latas, J. Stojek / Energy 153 (2018) 836e848
combustion engine. Due to the possible extensive improvement in
fuel consumption, hydraulic technology has primarily attracted
attention of the automotive industry [3e11]. Many papers have
been devoted to the optimal power management and torque con-
trol strategy minimizing fuel consumption and carbon dioxide
emission in hydraulic hybrid vehicles [11e17].
Hydraulic hybrid vehicles (HHV) use at least one reversible unit
(pump/motor) which works as a pump converting captured kinetic
energy into hydraulic energy during braking (filling the accumu-
lator vessel with fluid) and, then, as a motor driving the wheels
during acceleration. Hydraulic regenerative braking technology is
especially well adapted for off-road vehicles, heavy-duty trucks,
distribution trucks, refuse collection trucks, and urban buses with
frequent stop-and-go cycles [5e10].
Compared to electric batteries, hydraulic accumulators are
characterized by an even two orders of magnitude lower energy
storage density. Energy mass ratio equals approximately 4e10 kJ/kg
for an advanced hydraulic accumulator [4,18,19] and 300e500 kJ/kg
for Li-on electric battery packs [20,21]. The strength of the hy-
draulic accumulator lies in almost two orders of magnitude higher
power density and ability to work in conditions where highly-
dynamic frequent and short start-stop cycles occur. Power mass
ratio equals approximately 500e1000 W/kg for Li-on batteries
[21,22] and lies in the range 10000e100000 W/kg (depending on
the type) for hydraulic accumulators [19].
Hydraulic hybrids can more efficiently recover kinetic energy
than electric hybrids mainly due to smaller number of energy
conversions and lower mechanical losses. It was estimated that
more than 70% of the recovered kinetic energy of a braking hy-
draulic hybrid vehicle can be available for acceleration, whereas
regenerative braking efficiency of electric hybrids is less than 25%
[23e25].
In order to improve fuel consumption, the hybrid solutions of
different types used in vehicles have been adapted in construction
machinery due to great energy recovery potential [26,27]. Espe-
cially, a lot of research has been devoted to the hybrid technology in
hydraulic excavators. The recovered energy is mainly, due to its
largest recoverable amount, the boom gravitational potential en-
ergy, the energy created during braking of the swings, and the
surplus of the engine output energy.
Excavators and heavy off-highway working vehicles may be
equipped with a recovery system converting potential energy of the
boom into electricity stored in capacitors or batteries [28,29]. In a
purely hydraulic approach, the recovered energy is converted into
hydraulic form, stored in a hydraulic accumulator, and released, if
necessary, directly to system [30,31]. This requires additional
components, such as hydraulic motors and pumps used for reuse of
the recovered energy. The papers [32,33] present hybrid energy
recovery systems in excavators which combine the advantages of
the hydraulic accumulator and the electric rechargeable battery. In
the paper [32], potential energy of the boom is transformed into
both electric and hydraulic energy, with energy distribution
dependant on the control strategy related to the recovery time. In
the proposal presented in Ref. [33], the excess energy supplied
while contracting the boom cylinder is converted into electricity in
a generator driven by a hydraulic motor powered by oil from the
accumulator.
The Caterpillar 336E H is the industry's first hydraulic hybrid
excavator launched in 2013 [34]. The Hydraulic Hybrid Swing
System captures the swing braking energy in hydraulic accumula-
tors, the stored energy is re-used during upper-structure acceler-
ation. The 336E H is characterized by up to 25% greater fuel
efficiency than in the standard model without the regenerative
system.
Due to the large potential arising from cycling operation, there
837
are many market systems for energy recovery in passenger eleva-
tors. The Bucher Hydraulics offers hydraulic elevators with a
regeneration package capable of sending back up to 30% of drive
energy into the grid or super capacitor (Eco Line with SuperCap
[35]). The Eco Line e Orion ALPHA [35] is an energy saving hy-
draulic drive system with regeneration for elevators with a hy-
draulic counterweight for reduced power connection requirement.
Hydraulic counterweight in the form of a pressure accumulator is
more compact than a conventional counterweight. By reducing
load on the electrical drive, up to 80% energy saving is possible with
the Orion ALPHA system applied (including the accumulator and
other technical measures).
The paper [36] presents an interesting design of a regenerative
hydraulic elevator drive without the electric motor/generator
(replaced by a hydraulic transformer), with two variable displace-
ment pumps/motors and three hydraulic accumulators (the main
accumulator supplies fluid for actuation). The accumulators, oper-
ating as a hydraulic counterweight, provide power to the system. A
small auxiliary electric machine supplements energy lost due to
friction, leakage, etc. Control of the system driven by pre-charged
accumulators is obtained by varying displacement in the pumps/
motors. By eliminating mechanical/electrical energy conversion,
the architecture proposed in Ref. [36] yields less than 20% energy
input over the standard electro-hydraulic system.
In spite of many advantages of hydraulic hybrids, such as high
power density, efficient energy storage, fast charging and dis-
charging, reliability and cost effectiveness, the main drawback is
much lower capacity of the conventional hydraulic accumulators
relative to other technologies (e.g. electric batteries), which con-
stitutes a significant barrier in further development of the hydraulic
hybrid drives. Several attempts have been made in order to increase
the density of energy stored in the accumulators.
The first approaches to improving energy density in hydraulic
accumulators were directed towards achieving the thermodynamic
processes (i.e. compression and expansion of the gas contained in
the accumulator during charging and discharging) that would run
as isothermal as possible [37]. Another way to increase energy
density may be a change in the structure, like in a variable area
piston accumulator [38], double piston [19], or multi-chamber
accumulator [39]. The new approaches are based on the concept
of an open accumulator [40] and additional energy storage in the
kinetic rotational domain (cf. hydraulic flywheel-accumulator
presented in Refs. [41,42]).
Given the basic drawback of standard hydraulic accumulators,
the main goal was to develop a structure which would make it
possible to increase the density of stored energy.
The concept chosen for the study was HFA (hydraulic flywheel-
accumulator), which allows to increase the amount of stored en-
ergy by accumulating it both in the form of hydrostatic energy and
kinetic energy of the rotary motion [41,42]. From the formal point
of view, the HFA is a hydraulic piston accumulator that rotates, with
variable moment of inertia due to inflowing or outflowing oil.
Thanks to the synergy of two energy domains, a structure with a
significantly higher (even by an order of magnitude) density of the
stored energy may be obtained, compared to the conventional
accumulator.
The new hydrokinetic accumulator construction presented in
the paper can be treated as a generalization of the structure
described in Ref. [42]. However, a completely different solution of
the gas chamber allows to store energy of higher density. The
explanation of the basic difference between the constructions can
be found in Chapter 2 dedicated to the technical details of the
accumulator, which is a new, patented solution [43].
Except for the significant increase in energy density, an addi-
tional advantage of the HFA is that the pressure in the system can
838 W. Latas, J. Stojek / Energy 153 (2018) 836e848
be decoupled from the amount of the stored energy [41,42]. The use
of the hydraulic pump/motor with variable displacement allows to
control the pressure during accumulator charging and discharging.
In addition to presenting the construction and operating prin-
ciples of the new accumulator type, the work includes a simulation
of the operation of a hydraulic lift with energy recovery system
using the described hydrokinetic accumulator as an example of
possible application.
Corresponding pressure control algorithm is shown for the lift
operation, where the energy stored during lowering the weight,
which would be wasted in the system without energy recovery, was
then used during lifting process. For a cyclic working system such
as a passenger elevator, this would mean considerable energy
savings.
The algorithm determined allows to control the lowering and
lifting processes affected by the conditions imposed on the load
motion, the results of the numerical simulations of the energy
storage and extraction are given. The aim is not to present the
technical details of the lift, but to demonstrate the possibility of
controlled energy flow only by steering the variable displacement
pump.
The work does not cover strength calculations of the presented
accumulator components. A detailed overview of technical issues
necessary to consider when designing an HFA type accumulator can
be found in Ref. [42].
The presented accumulator may become a relevant component
of the hydrostatic systems with energy recovery. It can be used both
in the development of a vehicle with hydraulic hybrid drive and in
systems which accumulate energy derived from its recovery in
hydrostatic drive devices and machines and can compete with
currently used electro-hydraulic energy recovery systems.
2. Construction and operation principle of hydrokinetic
accumulator
The developed construction of the hydrokinetic accumulator of
the increased energy storage density consists of the flywheel of
variable moment of inertia. The flywheel is joined by a controlled
electromagnetic clutch with a switchable hydrostatic unit oper-
ating as a hydraulic pump or a motor of variable displacement. Such
accumulator system is schematically shown in Fig. 1.
The construction of the flywheel of variable moment of inertia
Fig. 1. Schematic presentation of the hydrokinetic accumulator: 1 e variable
displacement pump/motor, 2 e flywheel of variable moment of inertia.
(caused by the incoming or outflowing fluid), in the solution pro-
posed by the authors, consists of two coaxially installed cylinders
between which a ring-shaped piston is placed (Fig. 2).
The piston divides the space into two working chambers of the
accumulator, i.e. a gaseous and a fluid chamber. The chambers are
closed from both sides by covers twisted from two components.
Appropriately made flow channels in the cover components
together with live swivels ensure supplying the external chamber
of the flywheel with the working fluid (e.g. oil) from the hydrostatic
system. They also allow pre-filling of the chambers by a compressed
gas (e.g. nitrogen) to the needed pressure value.
Both, the ring-shaped piston and chamber covers are equipped
with sets of static-dynamic seals. Figs. 1, 4 and 5 schematically
present fluid and gas pressure distributions, parabolic and constant
respectively, on the right and left sides of the piston. Parabolic
distribution is the result of centripetal acceleration in the rotating
fluid. The effect of rotation on the gas pressure is neglected.
The proposed new construction of the hydrokinetic accumulator
differs from the corresponding design presented in Ref. [42] in
terms of the gas chamber solution. In the construction described in
the paper [42], the gas and oil chambers are located in the space
between the shaft and the housing. The use of internal cylinder
interior (Fig. 2) as part of the gas chamber enables gas volume to
increase considerably without significantly reducing moment of
inertia of the flywheel.
3. Hydrokinetic accumulator work modes
Energy storage and extraction processes e in the proposed so-
lution e can occur in three specific work modes: hydrostatic, ki-
netic, and hydrokinetic. The differences between the work modes
are explained in sections 3.1e3.3 on the basis of the description of
the accumulator charging process. The discharging process is per-
formed similarly, except that the direction of the hydraulic fluid
flow is changed.
3.1. Hydrostatic mode
Energy storage in the hydrostatic mode occurs when the motor
does not transfer torque on the accumulator flywheel shaft. Then
the external chamber of the flywheel is supplied with working fluid
(Fig. 3).
At the initial stage, at the lack of the flywheel rotational motion,
when the fluid pressure value on the right side of the ring-shaped
piston is smaller than the gas pressure on the left, the piston is in
the right extreme position, i.e. directly at the cover closing the
cylinder. At that stage, the whole space in the accumulator cylin-
ders is taken up by gas.
If the fluid pressure in the maintained system grows above the
assumed value of the preliminary gas pressure, the ring-shaped
piston starts shifting to the left. Thus, the flywheel external
chamber is filled with working fluid under pressure. The piston
movement continues until forces resulting from the pressures on
both piston surfaces counterbalance themselves. At the initial
angular velocity of the flywheel equal to zero, during the storage
process energy domain is not changed. The total energy stored in
the accumulator is solely hydrostatic. The cited way of energy
storage is most efficient, but the hydrostatic energy has limited
density.
If at the initial stage of the accumulator charging in the hydro-
static mode the flywheel angular velocity was not zero, it would be
decreasing during charging due to the increase of the flywheel
moment of inertia (in accordance with the conservation of angular
momentum principle). As a result, the kinetic energy would also be
decreasing.
 W. Latas, J. Stojek / Energy 153 (2018) 836e848
Fig. 2. Schematic of the flywheel of variable moment of inertia: 1 e external cylinder, 2 e internal cylinder, 3 e piston, 4 e left cover, 5 e right cover, 6 e tie rod.
Fig. 3. Principle of the accumulator operation in hydrostatic mode at the lack of
flywheel rotational motion.
3.2. Kinetic mode
When the accumulator motor is charged with working fluid, at
simultaneous lack of charging of the external chamber of the
flywheel due to the immobile piston, the accumulator operation
changes into kinetic mode (Fig. 4).
The accumulator energy e in this mode e increases as a result of
work performed only by the torque imposed on the shaft, which
leads to the increase of the flywheel angular velocity at simulta-
neous pressure decrease in the system (due to the centripetal ac-
celeration of the fluid; cf. section 5.1). In order to prevent the
working fluid from flowing out from the external chamber, the
application of the variable displacement motor is necessary.
Since in this work mode the hydraulic energy of the system is
converted into the kinetic energy of the rotating accumulator
flywheel, this method of energy storage is, due to greater energy
losses, less efficient than in the hydrostatic work mode. However,
the collected kinetic energy can be of higher density.
3.3. Hydrokinetic mode
When the accumulator operates in a mixed hydrokinetic mode
839
Fig. 4. Conceptual diagram of the accumulator operation in kinetic mode.
(Fig. 5), the working fluid simultaneously charges both compo-
nents, i.e. the flywheel external chamber and the hydraulic motor.
The third possible work mode constitutes simultaneous charging of
the accumulator partially with hydrostatic energy and partially
with kinetic energy.
Due to lack of equilibrium between the forces acting on its
surfaces, the piston shifts to the left, compresses gas and, simul-
taneously, takes an additional fluid portion from the system, which
consequently increases the moment of inertia of the accumulator
flywheel. The process ends when the forces acting on both surfaces
of the piston are in equilibrium.
3.4. Charging and discharging hydrokinetic accumulator
Charging the hydrokinetic accumulator (and so the energy
extraction) can proceed according to various algorithms of
switching between work modes, depending on the way in which
energy is supplied from the environment to the system.
840 W. Latas, J. Stojek / Energy 153 (2018) 836e848

Fig. 6. Conceptual diagram of the hydrostatic hybrid drive system with hydrokinetic
accumulator: Pm1, Pm2 e variable displacement pumps/motors, P e fixed displace-
ment pump.

various ways, depending on the assumed algorithm of cooperation

between the drive motor M and the accumulator.

5. Energy recovery in hydrostatic lift system with

hydrokinetic accumulator

In order to demonstrate operation of the hydrokinetic accu-

mulator with a flywheel of variable moment of inertia introduced
herein, a computational model of its application in a hydraulic lift
Fig. 5. Conceptual diagram of the accumulator operation in hydrokinetic mode.
system was developed. The lift system was chosen because the use
of hydraulic accumulators in stationary systems (such as elevators)
Density of the energy in the accumulator depends on the
character of the stored energy (only potential, only kinetic, or
mixed, potential and kinetic), the highest density can be obtained
for the accumulator charged with both forms of energy.
Extraction of the stored kinetic energy requires a prior discon-
nection of the rotating flywheel from the hydrostatic motor by
means of a controlled electromagnetic clutch, and changing it into
the pump work mode. When the pump is once more connected
with the flywheel, the hydrostatic energy is generated at the pump
output and supplies the system. For a similar hydrokinetic accu-
mulator with a fixed displacement pump, switching between
modes during charging for a case with constant regenerative power
supply (achieved during braking in a vehicle or lowering load in an
excavator) was presented in Ref. [41].

4. Examples of hydrokinetic accumulator applications

The hydrokinetic accumulator can find a wide range of appli-

cations wherever the energy demand of the systems with hydro-
static drives exhibits large differences. Such a situation occurs,
among others, when the central hydraulic aggregates intended for
supplying several receivers or driving systems of working machines
are used. The energy excess as well as the energy originating from
idle work cycles can be stored in the accumulator.
In Fig. 6 is shown the use of the hydrokinetic accumulator in a
hybrid drive system (the example is based on the similar model
presented in Ref. [41]). The energy obtained during vehicle braking
can then be returned to the system. In order to allow charging and
discharging of the accumulator according to an assumed routine,
the variable displacement pumps/motors Pm1 and Pm2 are used.
The example of the hydrokinetic accumulator application in a
Fig. 7. Conceptual diagram of the hydrostatic lift system with hydrokinetic accumu-
system of the hydrostatic lift is presented in Fig. 7. The energy lator: SH e hydraulic cylinders, R1, R2, R3 e directional control valves, ZM1 e relief
obtained during lowering of the load can be returned to the system valve, P e fixed displacement pump, Pm e variable displacement pump/motor, Sp e
during lifting process. The energy stored can be recovered in clutch, M e drive motor.
 W. Latas, J. Stojek / Energy 153 (2018) 836e848 841

Assuming constant density of the hydraulic fluid, the variable

moment of inertia of the flywheel is given by the formula:

prFL  
J ¼ J0 þ D4I  d4O x (2)
32

5.2. Model of hydrostatic lift with hydrokinetic accumulator

In order to study the processes of energy flow during the

Fig. 8. Computational diagram of the flywheel of variable moment of inertia.
is not limited by the relatively low energy density (compared to
other technologies), whereas such drawback is of much conse-
quence in mobile applications (such as excavators). A relatively
simple example displays the most important features of the hy-
drokinetic accumulator and associated energy flows.
When building a model of the hydrokinetic accumulator, a
number of simplified assumptions were made allowing to focus on
the problems of energy recovery, in order to demonstrate practical
benefits of the new structure. Several phenomena reducing the
overall efficiency of the system were neglected. The basic
assumption is omission of the mechanical and volumetric losses in
the pump/motor. The impact of these effects has been shown for
the accumulator of a similar flywheel design in Refs. [41,42].
Additionally, the losses due to friction in the bearings, friction
between the piston and cylinders, and fluid flow resistances in the
hydraulic circuit were not included. Energy losses occurring during
gas transformations in the chamber of the accumulator cylinder
and those resulting from slippage between layers of the liquid
(being the effect of flywheel acceleration) were also omitted in the
calculations.
5.1. Model of accumulator flywheel
The schematic of the flywheel of variable moment of inertia is
presented in Fig. 8. The parameters describing the flywheel (made
of aluminum) are collected in Table 1. The presented flywheel
construction is a generalization of the structures depicted in
Refs. [41,42] with other concepts of the gas and fluid chambers.
The mass moment of inertia of the accumulator flywheel before
feeding the fluid is a sum of the moments of inertia of the casing,
piston, and two covers (the moments of inertia of the tie rods are
negligible):
prMA h      i
J0 ¼ D4O  D4I þ d4O  d4I L þ D4I  d4O e þ 2D4 h
32
(1)
accumulator charging and discharging, the computational model
created does not take into account the operation of the lift drive
motor. This is justified by the results contained in Ref. [36], where
the passenger elevator system driven by energy stored in hydraulic
accumulators, without additional external power source, indicated
the possibility of a significant reduction in energy consumption
compared with standard solutions. Descent and ascent of the cab
was regulated via displacement control of the pumps/motors to
achieve the movement corresponding with the desired motion
profile.
The energy losses occurring in the system, in addition to the
aforementioned losses in the accumulator, were also neglected. A
simplified diagram of the hydrostatic lift with the hydrokinetic
accumulator is shown in Fig. 9. Additional parameters used in
further calculations are presented in Table 2, the variables con-
cerning operations of the examined system are listed in Table 3.
Decreasing potential and kinetic energy of the load during its
lowering causes the increase of hydrostatic and kinetic energy of
the accumulator, in a way depending on the assumed charging al-
gorithm. The reverse processes occur while discharging of the
accumulator during load lifting.
The relation between the fluid streams can be expressed as:
Q1 ¼ Q2 þ Q3 (3)
where individual streams are as follows:
Q1 ¼ Snv (4)
Q2 ¼ Au (5)
p  dx
Q3 ¼ D2I  d2O (6)
4 dt
Parameter A (Eq. (5)) is the displacement of the idealized pump/
motor in units of [m3/rad]. For the variable displacement unit, this
parameter may change over time, so hereafter will be used the
notation AðtÞ.
As indicated in Fig. 9, during lowering v > 0 and during lifting
v < 0. It is assumed that always u  0: for AðtÞ > 0, the hydraulic unit
works as a motor, and for AðtÞ < 0, it works as a pump.

Table 1
Accumulator flywheel parameters.

Parameter Symbol Value

external cylinder outer diameter [m] DO 0:380

external cylinder inner diameter [m] DI 0:360
internal cylinder outer diameter [m] dO 0:264
internal cylinder inner diameter [m] dI 0:244
cylinder length [m] L 0:200
piston width [m] e 0:010
cover width [m] h 0:010
cover diameter [m] D 0:430
mass moment of inertia of empty accumulator flywheel [kgm2] J0 0:512
mass density of cover, casing and piston material [kg/m3] rMA 2700:0
initial (precharge) gas volume in the accumulator [m3] V0 0:0178
842 W. Latas, J. Stojek / Energy 153 (2018) 836e848

where: H0 ¼ ðD2I  d2O ÞðL  eÞ þ d2I L. It can be seen that the pressure
in the system depends on the angular velocity of the flywheel.
In order to derive formula (7), the parabolic distribution of the
fluid pressure (with respect to the flywheel axis) and uniform
distribution of the gas pressure (due to negligible small inertial
forces) were utilized [41] with the assumptions of steady-state with
no fluid swirls and adiabatic gas transformation.
The torque applied from the pump/motor Pm on the accumu-
lator flywheel shaft is given by the formula:

T ¼ pS AðtÞ (8)
The system operation is described by the equation of translatory
motion of the mass m and by the equation of rotational motion of
the flywheel of variable moment of inertia:

dv
m ¼ mg  nSpS (9)
dt

du dJ
J þ u¼T (10)
dt dt
The equation describing the accumulator charging process
resulting from (3)e(6) should be added to equations (9) and (10).
After some rearrangements, the system of three differential equa-
tions of the first order is obtained:
0 0 1k 1
dv H r  
m ¼ mg  nS@p0 @  0
 A  FL
DI þ dO u A
2 2 2
dt H0  D2I  d2O x 16

Fig. 9. Computational diagram of the energy recovery system in hydrostatic lift with (11)
hydrokinetic accumulator.
 pr    du pr   dx
J0 þ FL D4I  d4O x þ FL D4I  d4O u
32 dt 32 dt
Table 2 0 0 1k 1
Lift system and accumulator parameters.
H r  
Parameter Symbol Value
¼ AðtÞ@p0 @  0
 A  FL
DI þ dO u A
2 2 2
(12)
H0  D2I  d2O x 16
hydraulic cylinder cross-section area [m2] S 0:005
number of hydraulic cylinders in the lift n 3
exponent of adiabatic gas transformation (nitrogen) k 1:4
p  dx
initial (precharge) gas pressure in the accumulator [Pa] p0 22:76,105 D2I  d2O ¼ Snv  AðtÞu (13)
mass density of hydraulic fluid [kg/m3] rFL 900:0
4 dt
mass of the lowered/lifted load [kg] m 3480:0 Dependent variables in the above system are: velocity of the
lowered (lifted) load v, flywheel angular velocity u, piston position
in the flywheel chamber x.
The expression for the pressure in the hydraulic system is ob-
The differential equations system (11)e(13) can be written in
tained from the equilibrium of forces acting on the piston (inertial
the form suitable for the numerical calculations:
force due to translatory motion of the piston along the flywheel axis
is neglected): 0 0 1k 1
dv nS @ @ H0 r  
0 1k ¼g p0   A  FL
DI þ dO u A
2 2 2
H r   dt m H0  D2I  d2O x 16
pS ¼ p0 @  0  A  FL D2I þ d2O u2 (7)
H0  D2I  d2O x 16
(14)

Table 3
Lift system and accumulator variables.

Variable Symbol

velocity of the lowered/lifted load [m/s] v

angular velocity of the accumulator flywheel [rad/s] u
piston position [m] x
actual mass moment of inertia of the accumulator flywheel with fluid [kgm2] J
actual gas volume in the accumulator [m3] V
fluid stream flowing out from the lift [m3/s] Q1
fluid stream flowing into the pump/motor Pm [m3/s] Q2
fluid stream flowing into the accumulator [m3/s] Q3
 W. Latas, J. Stojek / Energy 153 (2018) 836e848 843

 k   rffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
 
  
AðtÞp0 H0
þ r16FL
D2I þ d2O AðtÞu2  2Snvu rFL D2I þ d2O nS~vðtÞ  p4 D2I  d2O dx
du H0 ðD2I d2O Þx dt
¼   AðtÞ ¼ sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
 k (20)
dt J0 þ pr
32 DI  dO x
FL 4 4 4
~
mðaðtÞgÞ H0
þ p0
nS H0 ðDI dO Þx
2 2

(15)
In order to obtain the desired control function AðtÞ, it is neces-
dx 4ðSnv  AðtÞuÞ sary to determine the position of the piston xðtÞ. Transformations of
¼   (16)
dt p D2  d2 formula (15) lead to the equation:
I O

The total accumulator energy, being a sum of the kinetic energy dx f3 ðx; tÞ
¼ (21)
of rotational motion of the flywheel filled with fluid and potential dt f1 ðxÞ þ f2 ðx; tÞ
energy originating from work performed by the fluid during adia- The functions appearing in the above equation are given by the
batic gas compression, is given by the formula: following expressions:
1 pr        
E ¼ EK þ EP ¼J0 þ FL D4I  d4O x u2 8p0 kH0 D2I  d2O J0 þ pr 4 4
32 DI  dO x
FL
20 32 1 f1 ðxÞ ¼  
0 1k1    2
p H0 B @ (17) rFL D2I þ d2O H0  D2I  d2O x

H0
 A C
þ p0 @  1A 0 1k1 (22)
4 k1 H  D d x
2 2
0 I O
@ H
 0
 A
The system of equations (14)e(16) e in a general case e presents H0  D2I  d2O x
charging or discharging of the accumulator (during load lowering
or lifting) with both forms of energy simultaneously. These pro- 0 0 1k
cesses depend on the function AðtÞ, which defines the displacement p 
@2p0 @ H0
f2 ðx; tÞ ¼ D2W  d2Z   A
of the pump/motor Pm (Fig. 9). The previously described accumu- 4 H0  D2W  d2Z x
lator operating modes are obtained after adoption of some speci-
1
fied forms of this function. ~ðtÞ  gÞ
mða A
Substituting AðtÞ ¼ 0 into (15)e(16), the description of the hy- þ (23)
nS
drostatic mode is obtained.
The kinetic mode is given by the condition x ¼ x0 ¼ const, thus
it results from equation (16) that the following relation must be
8m~f ðtÞ
satisfied: AðtÞ ¼ SnvðtÞ=uðtÞ. This work mode is described by the ~ðtÞÞ~vðtÞ 
f3 ðx; tÞ ¼ mðg  a  
reduced system of two differential equations: nSrFL D2I þ d2O (24)
 pr   
0 0 1k 1
J0 þ FL D4I  d4O x
dv nS @ @ H r   32
¼g p0  0  A  FL D2I þ d2O u2 A
dt m H0  D2I  d2O x0 16 Additional notations: a ~ðtÞ ¼ d~v, ~f ðtÞ ¼ da~ are introduced in
dt dt
(20)e(24).
(18) 
Not every function v ðtÞ could be physically realizable without
 k the application of an additional force e except the forces from the
 
rFL hydraulic cylinders e acting on the load. Lowering may not proceed
u  16 DI þ dO vu
p0 H0 v 2 2
du H0 ðD2I d2O Þx0 with acceleration greater than g and, in turn, to lift the load to a
¼ Sn   (19)
dt J0 þ pr
32 DI  dO x0
FL 4 4 given height, sufficient amount of energy must be stored in the
accumulator working on its own. Additionally, the assumed func-
The other functions AðtÞ describing displacement of the pump/ tion ~vðtÞ must also comply with the initial conditions for x and u
motor are obtained based on the algorithm used for charging (Eq. (14)). The resulting control function AðtÞ determines the way of
(discharging) which can depend on the assumed conditions charging (or discharging) the accumulator with kinetic and po-
imposed on motion of the lowered (or lifted) load. tential energy.

5.3. Control of lowering and lifting processes 6. Investigation results

Velocity of the lowered (or lifted) mass depends on the function
AðtÞ describing displacement of the pump/motor, which controls
the fluid flow and affects the pressure in the system, providing the
force acting on the load. It would be an advantageous possibility to
obtain the assumed motion of the load e preferred from a practical
point of view e described by the formally arbitrary velocity func-

tion ~vðtÞ. It is therefore necessary for the assumed function v ðtÞ to
find the proper displacement of the pump/motor Pm via determi-
nation of the function AðtÞ. By controlling the flow, power is added
or subtracted to maintain the desired motion profile.
Substituting the angular velocity u, determined from formula
(14), into equation (16) yields the expression for the function AðtÞ
depending on the ~vðtÞ:
The numerical calculations were performed for the accumulator
flywheel described by the parameters collected in Tables 1 and 2.
Cylinder dimensions were assumed in such a way so as to obtain
the gas compression degree close to 2, in the moment of the
maximum left position of the piston.
The aim of the calculations is to determine the displacement of
the pump/motor, described by the function AðtÞ, which provides
the assumed velocity course ~vðtÞ of the lowered/lifted body. The
chosen velocity course must be compatible with the initial condi-
tions. First, the solution xðtÞ of the differential equation (21) is
determined, and the control function AðtÞ is obtained from formula
(20). The equation of the first order was solved numerically using
the Runge-Kutta-Verner method included in the IMSL® C Numerical
844 W. Latas, J. Stojek / Energy 153 (2018) 836e848

Libraries Version 2.0.

6.1. Lowering load and charging accumulator

In Figs. 10 and 11 are shown the assumed velocity course and the
corresponding displacement of the lowered load. For practical
reasons, zero velocity and zero acceleration were adopted at the
beginning (~vð0Þ ¼ 0, a~ð0Þ ¼ 0) and at the end of the lowering.
Additionally, in order to avoid singularity in equation (20), it is
ensured that ~f ð0Þ ¼ 0. The conditions mentioned are satisfied by
approximating the assumed velocity course ~vðtÞ using the third
degree polynomials.
The following initial conditions were taken: xð0Þ ¼ 0, uð0Þ ¼ 0. Fig. 11. Displacement of the lowered load during charging process.
In order to satisfy consistence of the assumed velocity course with
these conditions, the initial pressure in the accumulator equal to
p0 ¼ 22:76,105 N=m2 was taken. When lowering the load, the
hydrostatic unit e after earlier setting e operates as a motor.
The displacement of the motor in units of [cm3/rev], obtained
from the control function AðtÞ, which gives lowering of load ac-
cording to the assumed velocity course, is shown in Fig. 12.
In Figs. 13e16, the graphs of piston position, pressure in the
hydraulic system, rotational speed of the flywheel (in units of [rev/
min]), and potential, kinetic and full energy collected in the accu-
mulator are shown respectively.
While the piston moves and the pressure in the gas chamber
increases, due to increased angular velocity of the flywheel (and
resulting centripetal acceleration of the fluid), the system pressure
varies slightly. Fig. 12. Calculated displacement of the motor giving assumed velocity course of the
During charging, both kinetic and potential energy are lowered load.
increasing functions of time so there is no flow between the forms
of energy. At the end of the lowering process the kinetic energy
accounted for 74.3% of total energy.

6.2. Lifting load and discharging accumulator

During lifting the load, the hydrostatic unit operates as a pump.

Conditions taken at the beginning of the lifting process are as they
were obtained at the end of the lowering process: xð0Þ ¼ 0:143 m,
uð0Þ ¼ 428:46 rad=s (4091:49 rev=min), pressure in the system
equals pS ¼ 22:76,105 N=m2 .
In Figs. 17 and 18 are shown absolute value of the assumed ve-
locity course (during lifting v < 0) and the corresponding displace-
ment of the lifted load. For practical reasons, similarly to the
lowering process, zero velocity and zero acceleration (~vð0Þ ¼ 0, Fig. 13. Position of the accumulator flywheel piston during charging process (lowering
of the load).
~ð0Þ ¼ 0) at the beginning and at the end of lifting were adopted.
a
For the same value of the lifted mass as during lowering (m ¼
3480:0 kg), the assumed velocity course ~vðtÞ, approximated by the
third degree polynomials, is consistent with the initial conditions.
The displacement of the pump in units of [cm3/rev], obtained
from the absolute value of the control function AðtÞ (the hydraulic

Fig. 14. System pressure during charging process (lowering of the load).

unit works as a pump for AðtÞ < 0), which gives lifting of load ac-
cording to the assumed velocity course, is shown in Fig. 19.
In Figs. 20e23, the graphs of piston position, pressure in the
Fig. 10. Assumed velocity course of the lowered load.
 W. Latas, J. Stojek / Energy 153 (2018) 836e848
Fig. 15. Rotational speed of the accumulator flywheel during charging process
(lowering of the load).
Fig. 16. Component energies and total energy of the accumulator during charging
process (lowering of the load).
hydraulic system, rotational speed of the flywheel (in units of [rev/
min]), and potential, kinetic and full energy collected in the accu-
mulator are shown respectively.
During discharging, both kinetic and potential energy functions
of time are decreasing so there is no flow between the forms of
energy. At the end of lifting the kinetic energy accounted for 70.6%
of total energy. While the piston moves and the pressure in the gas
chamber decreases, due to decreased angular velocity of the
flywheel, the system pressure varies slightly.
Discontinuities in the graphs (Figs. 12 and 19) appear at the
inflection points of the function describing the assumed velocity
course ~vðtÞ, i.e. at the points of discontinuity of the function ~f ðtÞ.
6.3. Discussion
In the presented numerical calculations, the algorithm used to
control displacement of the pump/motor depends on the adopted
Fig. 17. Absolute value of assumed velocity course of the lifted load.
845
Fig. 18. Displacement of the lifted load during discharging process.
velocity course of the lowered/lifted load. The assumed velocity
course also determines acceleration of the lowered or lifted load. It
also indicates the resultant force acting on it. Therefore controlling
of the pump/motor ensuring the desired velocity course (by
establishing the variable displacement given by the function AðtÞ)
in practice means controlling the pressure in the hydraulic lift
system. Obviously, the pressure course cannot be arbitrary and
must lie in the achievable limits. The final state of the accumulator
charge depends on the pressure course in the system because it
results in division of the supplied energy into kinetic and potential
components.
The calculation results show that, by using the hydraulic pump/
motor of variable displacement (by means of a suitable displace-
ment control of the unit), charging or discharging of the accumu-
lator can be obtained even at a constant pressure in the system
despite the changes in the gas chamber pressure.
The energy stored in the accumulator is intended to support
operation of the main lift drive. The moment of switching on the
auxiliary system and the method of releasing the accumulated
energy depend on the adopted algorithm of cooperation which has
to take into account the state of charge and system pressure. The
presented calculation results relate to the system without the
external power supply. In the simulations performed it was
assumed that the stored energy amount was sufficient to lift the
weight without the need of switching on the main drive.
Simulation of the complete lift system would require including
an additional fluid stream from the main drive (motor M and pump
P depicted in Fig. 7), the other system architectures can also be
applied. The cooperation algorithms of the lift drive motor with the
accumulator would have to take into account the state of charge
and the value of load to be lowered and lifted. In practical appli-
cations, it would be necessary to use several hydrokinetic accu-
mulators controlled independently and additional installation of
Fig. 19. Calculated displacement of the pump giving assumed velocity course of the
lifted load.
846 W. Latas, J. Stojek / Energy 153 (2018) 836e848
Fig. 20. Position of the accumulator flywheel piston during discharging process (lifting
of the load).
Fig. 21. System pressure during discharging process (lifting of the load).
Fig. 22. Rotational speed of the accumulator flywheel during discharging process
(lifting of the load).
Fig. 23. Component energies and total energy of the accumulator during discharging
process (lifting of the load).
the gears between the pumps/motors and the flywheels.
The aim of the simulations was to investigate the energy flow in
the exemplary lift system and to present the possibility of regu-
lating pressure by displacement control of the accumulator pump/
motor, with neglected energy losses. The total energy supplied
from a source, due to losses, cannot be fully stored, and, similarly,
the total energy stored in the accumulator cannot be fully extracted.
The impact of the mechanical and volumetric losses in the hy-
draulic motor on the efficiency of the flywheel accumulator of a
similar operation principle to that presented herein has been
shown in Ref. [41], where charging process efficiency has been
estimated at 80%.
The maximal system pressure and rotational speed occurring in
the simulation of the lift unit with the hydrokinetic accumulator
are significantly lower (approximately 2 MPa and 4000 rev/min)
than the admissible values in hydraulic systems, so the energy
density is not high. At much higher pressure and rotational speed
(35 MPa and 25000 rev/min respectively) the accumulator of the
hydraulic flywheel type can achieve energy density even ten times
higher than a conventional accumulator [41], but mainly due to the
increase in the kinetic energy dependant on the casing material
density.
A comprehensive overview of the technical issues associated
with the design of the new type hydraulic flywheel accumulator of
a similar architecture to that described in the present paper has
been collected and discussed in Ref. [42]. Among others, the
calculation models for each of the energy loss phenomena associ-
ated with the operation of the accumulator have been presented. In
addition to the mechanical and volumetric losses in the pump/
motor, the following were taken into account: losses in live swivel,
flow losses in fluid ports, losses due to fluid swirl, power dissipation
due to friction, and power dissipation due to aerodynamic drag. The
overall efficiency of the accumulator presented in Ref. [42] reaches
75%. Due to the construction similarity (the same principle of
operation but with different design of the gas chamber), the main
conclusions given the accumulator efficiency presented in Ref. [42]
also apply to the construction shown in the present paper.
Additional phenomena influencing efficiency and storage
capability are gas compressibility and thermal losses. For very high
pressure, the differences exist between the behavior of ideal and
real gases so it is necessary to use the other state equation than
adiabatic describing the thermodynamic behavior of the gas
[44,45].
During the project stage, attention should be paid to the rim
stress, gyroscopic torque in mobile applications (pitch, yaw, or roll
of the vehicle) and complex live swivel design (high both system
pressure and angular velocity).
Compared to the design shown in Ref. [42], the construction
presented herein has greater volume of the gas chamber (for the
same external dimensions) obtained by using the inside of the in-
ner cylinder, increasing the amount of the potential energy stored.
The use of the interior of the inner cylinder also reduces the weight
of the flywheel without significant reduction in kinetic energy.
7. Conclusions
The new construction of the hydrokinetic accumulator pre-
sented in the paper combines features of a mechanical KERS (Ki-
netic Energy Recovery System) and a conventional hydraulic
accumulator. The method in which both potential and kinetic en-
ergies are stored not only allows significant increase in energy
density, but also decoupling the state of charge from the pressure in
the hydraulic system.
The simulation results confirm that application of the hydroki-
netic accumulator for energy storage is possible in hybrid vehicles,
 W. Latas, J. Stojek / Energy 153 (2018) 836e848
heavy working machines, and systems of presses and lifts. Accu-
mulation of energy in two forms enables wide variety of possible
hybrid hydraulic system architectures. The ability to control the
pressure by varying displacement in the pump/motor (DC e
displacement control) can be utilized in semi-active vibration
dampers and shock absorbers.
The next stage of the authors' study will complement the pre-
sented mathematical model by taking into account mechanical and
volumetric losses in the pump/motor, flow losses in the hydraulic
circuit, and thermal losses during transformations in the gas
chamber. In order to use the hydrokinetic accumulator in practice,
the control algorithm presented in the paper should be extended to
include cooperation with an external power source.
In addition to the simulation results presented in the work, it is
necessary to build and study a physical model of the proposed
hydrokinetic accumulator, which would be equipped with appro-
priately selected measuring transducers (including pressure, flow
rate, and rotational speed ones). The results obtained from the
experimental tests could be used to verify the developed structure
and its further development. A very important issue is the deter-
mination of energy losses and the estimation of possible efficiency
of the energy transformations.
Nomenclature
DO external cylinder outer diameter
DI external cylinder inner diameter
dO internal cylinder outer diameter
dI internal cylinder inner diameter
L cylinder length
e piston width
h cover width
D cover diameter
J0 mass moment of inertia of the empty accumulator
flywheel
rMA mass density of cover, casing and piston material
V0 initial (precharge) gas volume in the accumulator
S hydraulic cylinder cross-section area
n number of hydraulic cylinders in the lift
k exponent of adiabatic gas transformation (nitrogen)
p0 initial (precharge) gas pressure in the accumulator
rFL mass density of hydraulic fluid
m mass of the lowered/lifted load
v velocity of the lowered/lifted load
u angular velocity of the accumulator flywheel
x piston position
J actual mass moment of inertia of the accumulator
flywheel with fluid
V actual gas volume in the accumulator
Q1 fluid stream flowing out from the lift
Q2 fluid stream flowing into the pump/motor Pm
Q3 fluid stream flowing into the accumulator
g constant of gravity
Appendix
The ordinary differential equations were solved numerically
using the Runge-Kutta-Verner method included in the IMSL® C
Numerical Libraries Version 2.0.
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