Energy consumption and temperature rise are challenging in traditional high-power hydraulic pump/motor loading systems. This study develops a novel loading system configuration where energy can be regenerated by mechanical compensation. A compound loading method is proposed to implement static loading with displacement control and dynamic loading with valve control, respectively. This method combines the high energy-regeneration capability of the displacement control and the fast dynamic response of the valve control. Pressure controllers are designed based on system modeling and characteristics analysis. For static loading, a proportional–integral–derivative controller is employed, and the variation of rotational speed is taken into consideration to reduce overshoot and oscillation. For dynamic loading, an off-line learning method is developed by using least square calibration to keep the relief flow rate at a low level without flow meters. An experimental setup of a 300-kW-class loading system is manufactured, and experiments in various loading modes are performed. The results show that the designed system and controllers have accurate pressure tracking performance and low energy consumption.

中文翻译：

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具有能量再生的300kW级液压泵/马达加载系统的设计、建模和压力控制

在传统的大功率液压泵/马达加载系统中，能耗和温升具有挑战性。本研究开发了一种新型加载系统配置，其中能量可以通过机械补偿再生。提出了一种复合加载方法，分别实现带位移控制的静态加载和带阀门控制的动态加载。这种方法结合了排量控制的高能量再生能力和阀门控制的快速动态响应。基于系统建模和特性分析设计压力控制器。对于静态载荷，采用比例-积分-微分控制器，并考虑转速的变化以减少超调和振荡。对于动态加载，通过使用最小二乘校准开发了一种离线学习方法，以在没有流量计的情况下将泄压流量保持在较低水平。制作了300kW级加载系统的实验装置，并进行了多种加载模式的实验。结果表明，所设计的系统和控制器具有准确的压力跟踪性能和低能耗。