Analysis of optimal operating points for electro-hydraulic energy system in aircraft mission profiles

Authors

  • Weilin Fu Beihang University, Beijing 100191, China
  • Jiming Ma Beihang University, Beijing 100191, China
  • Xiaohua Gou AVIC Liyuan Hydraulic Co., Ltd., Guizhou 550018, China
  • Xu Ma AVIC Liyuan Hydraulic Co., Ltd., Guizhou 550018, China
  • Yongling Fu Beihang University, Beijing 100191, China
Article ID: 453
293 Views

DOI:

https://doi.org/10.18686/cest453

Keywords:

electro-hydraulic system; PMSM; hydraulic pump; efficiency optimization

Abstract

Abstract: In the future, all-electric/more-electric aircraft will gradually adopt electric pump sources to replace traditional hydraulic systems centered on engine-driven pumps. The core components of the electric hydraulic energy system, namely permanent magnet synchronous motors and constant-pressure variable displacement pumps, have the problem of low efficiency at some operating points. Focusing on a typical electric energy system architecture, this paper studies the quantitative relationship between its efficiency and system states such as rotational speed, current, torque, pressure, and displacement. Moreover, with the goal of maximizing efficiency in the full load range, and taking motor speed and current as optimization variables, a calculation model for the optimal operating point is constructed within the scope of system design constraints. Finally, taking the electric hydraulic energy system of an actual aircraft as the research object, a state equation covering all its efficiency-related variables is established based on Matlab. With the optimization goal of the highest efficiency, the optimal combination of speed and displacement when the load flow changes in a wide range is given, and verified based on experimental data. Compared with the traditional constant-speed operation mode, the range of the high-efficiency operating area of the system can be increased by about 5.2 times after efficiency optimization.

Downloads

Published

2025-09-23

How to Cite

Fu, W., Ma, J., Gou, X., Ma, X., & Fu, Y. (2025). Analysis of optimal operating points for electro-hydraulic energy system in aircraft mission profiles. Clean Energy Science and Technology, 3(4), 453. https://doi.org/10.18686/cest453

Issue

Vol. 3 No. 4 (2025)

Section

Article

License

Copyright (c) 2025 Author(s)

Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License.

References

1. Nostrani MP, Oliveira e Silva D, Krus P, De Negri VJ. A method for designing of hydraulic actuators using digital hydraulic pump and multichamber cylinder. Journal of Dynamic Systems, Measurement, and Control. 2023; 145(8): 081003. doi: 10.1115/1.4062636 DOI: https://doi.org/10.1115/1.4062636

2. Yang M, Yan G, Ai C, Liu X. Energy efficiency optimization of electric hydraulic loader with variable speed variable displacement power source. Scientific Reports. 2025; 15(1): 5257. doi: 10.1038/s41598-025-89731-5 DOI: https://doi.org/10.1038/s41598-025-89731-5

3. Wang X, Wang Q. Optimized composite braking energy recovery control for plug-in hybrid electric vehicle with a 3-speed dedicated hybrid transmission. International Journal of Automotive Technology. 2025. doi: 10.1007/s12239-025-00303-y DOI: https://doi.org/10.1007/s12239-025-00303-y

4. Liu H, Liu J, Yang H, er al. Research on bivariate control of high-speed electric drive pumps for battery electric excavators. Construction Machinery and Equipment. 2025; 56(4): 53-57.

5. Liu H, Zhang X, Quan L, Zhang H. Research on energy consumption of injection molding machine driven by five different types of electro-hydraulic power units. Journal of Cleaner Production. 2020; 242: 118355. doi: 10.1016/j.jclepro.2019.118355 DOI: https://doi.org/10.1016/j.jclepro.2019.118355

6. Maré JC. Review and analysis of the reasons delaying the entry into service of power-by-wire actuators for high-power safety-critical applications. Actuators. 2021; 10(9): 233. doi: 10.3390/act10090233 DOI: https://doi.org/10.3390/act10090233

7. Lyu D, Zhao S, Zeng S, et al. Key technologies and challenges of high-performance servo-motor-pumps. Acta Aeronautica et Astronautica Sinica. 2024; 45(15): 630225. doi: 10.7527/S1000-6893.2024.30225

8. Yang Y, Xia L, Zhang W, et al. Application of active disturbance rejection control in electro hydraulic actuator position servo system. Machine Tool & Hydraulics. 2023; 51(4): 113-117. doi: 10.3969/j.issn.1001-3881.2023.04.020

9. Yang J, Liu B, Zhang T, et al. Application of energy conversion and integration technologies based on electro-hydraulic hybrid power systems: A review. Energy Conversion and Management. 2022; 272: 116372. doi: 10.1016/j.enconman.2022.116372 DOI: https://doi.org/10.1016/j.enconman.2022.116372

10. Wen Y, Teng S, Li Q, et al. Investigating the symmetric control of a hydraulic system based on status feedback. Symmetry. 2025; 17(2): 246. doi: 10.3390/sym17020246 DOI: https://doi.org/10.3390/sym17020246

11. Du H, Li H, Ding K, et al. Research on energy saving and control characteristics of back pressure controllable variable speed pump controlled steering system for heavy vehicles. Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering. 2024; 239(9): 4120-4134. doi: 10.1177/09544070241265161 DOI: https://doi.org/10.1177/09544070241265161

12. He X, Li X, Min L. Research on electrohydraulic actuator brake system with distributed oil source. Hydraulics Pneumatics & Seals. 2020; 40(11): 47-50.

13. Yu Y, Do TC, Park Y, Ahn KK. Energy saving of hybrid hydraulic excavator with innovative powertrain. Energy Conversion and Management. 2021; 244: 114447. doi: 10.1016/j.enconman.2021.114447 DOI: https://doi.org/10.1016/j.enconman.2021.114447

14. Zhang C, Wang L, Li H. Optimization method based on process control of a new-type hydraulic-motor hybrid beam pumping unit. Measurement. 2020; 158: 107716. DOI: https://doi.org/10.1016/j.measurement.2020.107716

15. Zhao L, Ge L, Yang F, et al. Operating characteristics of variable speed fixed pump based on torque control. Chinese Hydraulics & Pneumatics. 2024; 48(10): 21-27. doi: 10.11832/j.issn.1000-4858.2024.10.003

16. Yan Z. Research on dynamic and energy efficiency characteristics of constant pressure pump driven by two kinds of variable speed motor. Machine Tool & Hydraulics. 2023; 51(6): 36-40.

17. Yan Z. Characteristics of high energy-efficient Electro-hydraulic power source driven by servo motor and variable pump. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science. 2023; 237(7): 1525-1536. doi: 10.1177/09544062221123952 DOI: https://doi.org/10.1177/09544062221123952

18. Goman VV, Oshurbekov SK, Kazakbaev VM, et al. Comparison of energy consumption of various electrical motors operating in a pumping unit. Electrical Engineering & Electromechanics. 2020; 1: 16-24. doi: 10.20998/2074-272X.2020.1.03 DOI: https://doi.org/10.20998/2074-272X.2020.1.03

19. Yan Z, Ge L, Quan L. Energy-efficient electro-hydraulic power source driven by variable-speed motor. Energies. 2022; 15(13): 4804. DOI: https://doi.org/10.3390/en15134804

20. Du L, Luo YL, Zhou SX, et al. Energy-saving simulation analysis of hydraulic system of hybrid power exca-vating manipulator. Machine Tool & Hydraulics. 2023; 51(7): 140-145.

21. Xu Z, Hua L, Liu Y. Energy saving and performance enhancement of hydraulic fineblanking press assisted with controllable hydraulic accumulator for sustainability. The International Journal of Advanced Manufacturing Technology. 2024; 131(3): 1119-1136. doi: 10.1007/s00170-024-13082-0 DOI: https://doi.org/10.1007/s00170-024-13082-0

22. Sumit, Gupta D, Juneja S, et al. Energy saving implementation in hydraulic press using industrial Internet of Things (IIoT). Electronics. 2022; 11(23): 4061. doi: 10.3390/electronics11234061 DOI: https://doi.org/10.3390/electronics11234061

23. Wei L, Lu Q, Zhan P, et al. Research on energy consumption characteristics of hydraulic cylinders controlled byvariable displacement hydraulic pumps driven by variable speed motor. Machine Tool & Hydraulics. 2025; 53(1): 180-186, 222.

24. Yang H, Su L, Li H, et al. Energy consumption optimization analysis of electric excavator based on fully distributed architecture and dual-variable control. Machine Tool & Hydraulics. 2025; 53(4): 88-93.

25. Lin J, Chen C, Wang D. Harmonic suppression strategy of permanent magnet synchronous motor considering iron loss. Journal of Hefei University of Technology: Natural Science. 2023; 46(2): 145-151.

26. Dong C, Xia Y, Sun D, et al. Analysis of loss on permanent magnet servo motor with high speed. Micromotors. 2021; 54(3): 36-40.

27. Zhao LF, Zhang T, Gu JM. Friction torque analysis and optimal design of angular contact ball bearing for high-precision aerospace instrument. Bearing. 2025; 4: 11-21.

28. Li L, Yuan H, Zhang Z, et al. Research on friction characteristics of textured surface slipper pairs of axial piston pumps. Lubrication Engineering. 2025; 50(6): 23-30.