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Control of diesel generator in series hybrid working machine : design and Implementation

Rintamäki, Juho (2025)

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Rintamäki, Juho
2025
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Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi:amk-2025060921728
Tiivistelmä
This thesis addresses the control of a diesel generator in a prototype series hybrid wheel loader retrofitted at Tampere University, focusing on optimizing engine efficiency and battery life. The research question explores how to develop and implement high-level control to coordinate the diesel engine and generator effectively within this hybrid system.

The aim is to design a working high-level control for the diesel generator in the 'sWille' wheel loader, sponsored by Tampere University. The purpose is to enable efficient operation considering battery life and power demand, with objectives of achieving energy efficiency and modifiability. A rule-based power follower strategy was developed using Simulink and Stateflow, incorporating an efficiency map for optimal engine operation. The methodology involved a simulation followed by implementation and testing on the actual machine.

The developed control algorithm was implemented and tested on the prototype using an auxiliary hydraulic pump to simulate load. It successfully managed engine modes, including idling to prevent battery overcharging, based on SOC, power demand, and battery temperature. The diesel generator and high-voltage system functioned as intended, validating the algorithm’s operational effectiveness.

The thesis demonstrates the feasibility and effectiveness of a rule-based control strategy for early deployment of hybrid working machines. It underscores the critical role of component sizing, particularly the engine and electric machines, in achieving optimal efficiency. The work provides a foundation for future research, suggesting refinement of control parameters, integration of advanced strategies like optimization-based methods, and upgrading components for enhanced performance.
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