Hydraulic systems in mobile machinery often face extreme torque peaks during operation. To handle these situations, engineers traditionally select hydraulic motors based on the worst-case scenario—such as moving a machine up a steep 30-40% gradient.
However, designing for this rare condition often results in oversized motors that are inefficient and costly.
Poclain’s HEVO Booster technology solves this problem by providing additional torque only when needed, eliminating the need for oversized motors while maintaining efficiency.
Before moving into how HEVO Booster works, let’s first understand the fundamental challenge of hydraulic motor torque selection and why this innovation is necessary.
Hydraulic Motor Torque and the Design Challenge
The torque (T) of a hydraulic motor is calculated using the formula:
Where:
- ΔP (Pressure Difference) = Inlet Pressure – Outlet Pressure (bar)
- D (Displacement) = Motor Displacement (cc/rev)
- 20π is a constant derived from unit conversion.
When selecting a hydraulic motor, engineers must ensure it provides sufficient torque under worst-case conditions, such as when a machine is climbing a steep gradient. In such cases, the only way to generate enough torque is by:
- Increasing ΔP (operating at a higher pressure)
- Increasing Displacement (using a larger motor)
However, the worst-case scenario happens only occasionally. If we design the motor based on that condition, we end up with a larger displacement motor that runs inefficiently most of the time. This leads to higher costs, unnecessary fuel consumption, and wasted hydraulic power.
Poclain, a leader in hydraulic innovations, has introduced the HEVO Booster, a cutting-edge technology designed to enhance torque performance while optimizing energy efficiency.
HEVO Booster
What is it?
The HEVO Booster is a pressure-boosting technology that provides additional torque when needed, ensuring smooth operation even in demanding conditions. Unlike traditional hydraulic systems that must be oversized to handle peak torque requirements, the HEVO Booster delivers extra torque only when necessary, optimizing efficiency without overdesigning the system.
This innovative technology enables hydraulic motors to temporarily increase operating pressure up to 800 bar (11,600 psi) without modifying the main hydraulic circuit. This feature makes it an ideal solution for applications that experience sudden torque peaks, such as heavy-duty construction equipment, forestry machinery, and industrial vehicles.
How does it Work?
The HEVO Booster is designed to activate automatically when a high torque peak occurs. Here’s how it works:
- Detecting Torque Demand: When a machine encounters heavy resistance (e.g., compacting soil, climbing a slope, or moving a large load), the system identifies the increased torque requirement.
- Activating the Booster: The HEVO Booster temporarily increases the internal pressure of the hydraulic motor, boosting torque without requiring additional input from the hydraulic pump.
- Returning to Normal: Once the torque demand decreases, the system returns to its normal operating state, reducing unnecessary energy consumption.
By providing extra torque on demand, the HEVO Booster eliminates the need for oversized motors, reducing weight, cost, and fuel consumption.
What are the Benefits?
Poclain’s HEVO Booster offers several key advantages over traditional hydraulic systems:
- Improved Efficiency: Reduces overall system energy requirements by activating additional torque only when needed, leading to better fuel economy.
- Enhanced Performance: Increases machine productivity by allowing it to handle peak loads seamlessly without requiring an oversized motor.
- Compact Design: Eliminates the need for larger, heavier components, making machines more agile and easier to operate.
- Lower Operating Costs: Reduces fuel consumption and extends the lifespan of hydraulic components by minimizing unnecessary stress.
- Seamless Integration: Available as an integrated solution within Poclain’s HEVO motors or as a standalone unit, making it compatible with existing hydraulic systems.
Where it can be Used?
Poclain’s HEVO Booster technology is suitable for various industries and applications, including:
- Construction Equipment: Excavators, compactors, and wheel loaders benefit from additional torque when working on uneven terrain or handling heavy loads.
- Agriculture Machinery: Tractors and harvesters experience better efficiency when plowing, lifting, or pulling loads in demanding field conditions.
- Mining and Forestry Vehicles: Machines operating in harsh environments gain improved traction and control.
- Industrial Applications: Hydraulic presses, material handling equipment, and other machinery that requires variable torque benefit from optimized energy use.
Vibratory asphalt rollers compacting a freshly laid road surface.
Case Study: HEVO Booster in Heavy Compaction Equipment
In the compaction industry, traditional tandem rollers often require oversized motors to handle rare peak loads. This results in inefficiencies during normal operation. With the HEVO Booster, Poclain has optimized the motor design by using a smaller displacement motor that efficiently operates under normal conditions while still delivering peak torque when necessary.
Results:
- Up to 10% fuel savings during operations.
- Improved load-handling capabilities without increasing system complexity.
- Extended component life due to reduced strain on hydraulic circuits.
Final Thoughts
Poclain’s HEVO Booster is a game-changer for hydraulic-driven machinery, offering a smart, energy-efficient solution to handle sudden torque demands. By enhancing performance without increasing energy consumption, it represents the future of hydraulic power optimization.
For industries that rely on heavy machinery, adopting HEVO Booster technology can lead to better efficiency, cost savings, and a more sustainable operation. As hydraulic technology continues to evolve, Poclain remains at the forefront, delivering innovations that push the boundaries of performance and efficiency.
Want to Learn More?
If you’re interested in integrating the HEVO Booster into your hydraulic systems, visit Poclain’s official website or contact their experts for more information.
