Beatrice Lang
Hydrostatic drives are an excellent means of power transmission, especially when variable output speed is required. They are known to outperform mechanical and electrical variable-speed drives and gear-type transmissions, offering fast response times, precise speed control, and infinite variability. Despite their superior performance, they are often more expensive than their mechanical counterparts. This has led some people to explore the possibility of converting hydrostatic drives to electric ones, especially in the context of tractors and cars, to save money and improve performance.
| Characteristics | Values | |
|---|---|---|
| Why convert hydrostat drive to electric? | Hydrostatic drives are costly compared to mechanical drives. | |
| Hydrostatic drives are also not easily available for purchase. | ||
| Electric drives can be more efficient and have a wider speed range. | ||
| Converting an existing hydrostatic drive vehicle to electric may be more cost-effective than buying a new electric vehicle. | ||
| How to convert hydrostat drive to electric | Lawn tractors with hydrostatic drives can be converted using a shunt motor. | |
| The electric motor can power a hydraulic pump and then a hydraulic motor that is direct-drive into a differential. | ||
| The hydrostatic transmission can be varied by regulating the stroke to control the rotor speed. | ||
| The drive train can be coupled with a synchronous generator operating at a constant speed, eliminating the need for frequency converters and transformers. |
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What You'll Learn
Electric motors and speed controllers
When considering electric motors, it's essential to select one that matches the specific requirements of your application. Factors such as duty cycle, final-drive ratio, rolling radius, and primer-mover speed should be taken into account to ensure optimal performance. Additionally, the type of electric motor can vary, including options like Geroler, geroter, gear, piston, and vane motors, each with unique characteristics and suitability for different operating conditions.
Speed controllers are another crucial aspect of electric drives, offering the ability to regulate the speed, power, and torque of the system. Hydrostatic drives, for instance, provide a wide speed range and simple controls, making them a popular choice for applications requiring variable output speeds. The variable displacement feature of hydrostatic drives helps fine-tune speed, power, and torque to meet specific needs.
In the context of converting a hydrostatic drive system to electric, it's important to understand the unique characteristics of the hydrostatic system. Hydrostatic drives typically consist of a hydraulic pump-motor combination, offering stepless speed change and excellent control capabilities. By converting to an electric drive, you can benefit from improved efficiency, especially with constant-power, variable-torque transmissions. Electric drives also offer the advantage of being able to convert mechanical energy into electrical energy, providing opportunities for energy recovery or alternative power sources.
When undertaking such a conversion, it's crucial to carefully select the appropriate electric motor and speed controller combination to match the performance characteristics of the original hydrostatic drive. This includes considering the speed range, torque capabilities, and control mechanisms required for your specific application. Additionally, ensuring compatibility between the electric motor and the existing drive components is essential for a seamless integration and optimal performance in the converted system.
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Hydrostatic drive systems
Hydrostatic drives convert mechanical power into fluid power and then into shaft power. They are generally made up of a hydraulic pump and motor combination, with the pump connected to the prime mover, generating fluid flow to run the hydraulic motor. The hydraulic pump runs the motor using fluids, and the speed and direction of the motor are determined by the variable displacement hydraulic pump. The pump is controlled by the crossport relief valve settings, which also determine the maximum pressure going to the motor. The motor case drain flow should be checked and recorded for future troubleshooting.
There are two main types of hydrostatic drive systems: fixed displacement and variable displacement. The former is best for applications with a constant output velocity, while the latter is used for variable output velocity applications. Based on the configuration of the hydraulic pump and motor, hydrostatic drives can also be classified as in-line, U-shaped, S-shaped, or split. In an in-line configuration, the variable pump and constant displacement motor are connected directly in line. In a U-shaped configuration, the motor is placed below the pump, and the input shaft and motor shaft rotate in the same direction. The S-shaped configuration is similar, but the motor is placed behind the pump. In a split configuration, high-pressure hoses separate the motor and pump.
Hydrostatic drives are often preferred over gear-based drives due to their step-less speed change capabilities and continuous power curve. They offer fast responses, precise speed control under varying loads, and variable speed control from zero to maximum. They can also increase available torque without shifting gears. However, a major drawback is the higher cost compared to mechanical systems.
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Conversion cost
The cost of converting a hydrostat drive to electric depends on several factors, including the type of vehicle, the complexity of the conversion, and the choice of parts. While it may be a cheaper alternative to buying a new electric vehicle, the conversion process can still be costly, especially for those without the necessary mechanical and electrical expertise.
For those considering converting their car to electric, there are two types of kits available: custom kits tailored to specific vehicle models and universal kits that can be installed in a range of vehicles. Universal kits typically start at around $8,000, excluding the battery, which can cost an additional $1,000 to $3,000. Custom kits, while more expensive, include all the necessary components, such as the drive system and battery setup, designed specifically for a particular model.
Converting a tractor to electric is also an option, and there are forums dedicated to discussing such conversions. While some tractor owners opt for a complete electric conversion, others explore hybrid setups, such as combining a hydrostatic drive with a forklift pump motor. The cost of a hydrostatic pump motor can be a significant drawback for hobbyists, with some considering salvage yards and scrap yards as potential sources for reasonably priced parts.
While the upfront cost of conversion can be substantial, it is important to consider the long-term savings and environmental benefits of electric vehicles. Electric cars have reduced running costs, are more environmentally friendly, and can offer improved performance compared to older combustion engine vehicles. Additionally, converting a classic car to electric can be a fun and unique project, providing a cost-effective way to future-proof your vehicle.
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Efficiency loss
The conversion of a hydrostat drive system to an electric drive system can result in efficiency loss due to various factors. Firstly, the inherent efficiency of the components involved, such as the pump and motor, plays a significant role. For example, a gear pump typically has an efficiency of around 75-80%, and this value decreases over the pump's lifetime. This means a significant portion of the energy is wasted as heat, resulting in a loss of overall system efficiency.
Secondly, the operating parameters of the pump and motor, such as pump speed, load torque, and supply flow rate, influence the efficiency of the hydrostatic drive. Small losses in the pump and motor can accumulate to impact the overall system performance. Therefore, it is essential to consider the characteristics of the various loss coefficients of these components when predicting the efficiency of the hydrostatic drive.
Moreover, the efficiency of the electric motor itself should be considered. Electric motors are rated based on power consumption rather than power output. For instance, an electric motor with an efficiency of 85% and a 10-hp rating will produce 8.5 hp, with the remaining 1.5 hp lost as heat. This loss in efficiency needs to be accounted for when converting to an electric drive system.
Additionally, the control mechanisms required for an electric drive system can impact efficiency. Hydraulic systems offer the ability to vary torque and speed, as well as reverse direction, with simple valving. In contrast, achieving the same level of control with an electric motor may require sophisticated electronic control systems, which can introduce complexities and potential sources of efficiency loss.
Lastly, the specific application and operating conditions can influence efficiency. For example, in the case of converting a tractor with a hydrostatic drive system, factors such as terrain type, speed, and load will affect the overall efficiency of the electric drive system. Therefore, it is essential to consider the unique characteristics and requirements of the application when assessing efficiency loss during the conversion from a hydrostat drive to an electric drive.
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$259.5
Hydrostatic transmission
The basic configuration of an HST involves connecting the corresponding pump ports with their motor counterparts. However, this initial setup is impractical due to potential cavitation and uncontrolled case pressures. To address this, circuit elements must be added to provide the necessary pressure control and prevent damage to the machines.
The pump in an HST is built into the transmission and is spun by the engine to create pressure. This pressure is then redirected by the pedal to spin the axle. The hydrostatic transmission can work bidirectionally, where the pressure can drive the wheels, or the wheels can build the pressure.
HSTs are commonly employed in construction equipment, where the main hydraulic pumps are self-controlled by the system working pressure through hydro-mechanical load sensing systems. This pressure-dependence can impact energy efficiency, and one way to improve machine performance is by replacing traditional hydro-mechanical load sensing systems with electronic load sensing systems.
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Frequently asked questions
Converting hydrostat drive to electric can be more cost-effective than buying a new electric tractor. It also allows for more precise speed control and faster response times.
Hydrostat drives are more expensive than their mechanical counterparts, and the conversion process may be complex and time-consuming.
Lawn tractors with hydrostatic drives can be converted by using a shunt motor. The hydrostatic pump can be replaced with an electric drive, and the transmission, controller, and speed controllers can be eliminated.
Online forums and communities dedicated to DIY electric cars and tractors can provide valuable information and support for those interested in converting hydrostat drive to electric.
