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Excavator Energy-saving Efficiency Based on Diesel Engine Cylinder

Deactivation Technology

Article  in  Chinese Journal of Mechanical Engineering · September 2012

DOI: 10.3901/CJME.2012.05.897

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 CHINESE JOURNAL OF MECHANICAL ENGINEERING
Vol. 25, No. 5, 2012 ·897·

DOI: 10.3901/CJME.2012.05.897, available online at www.springerlink.com; www.cjmenet.com; www.cjmenet.com.cn

Excavator Energy-saving Efficiency Based on Diesel Engine Cylinder

Deactivation Technology

YANG Jing1, QUAN Long1, 2, *, and YANG Yang 1

1 Key Laboratory of Advanced Transducers and Intelligent Control System of Ministry of Education,
Taiyuan University of Technology, Taiyuan 030024, China
2 The State Key Lab of Fluid Power Transmission and Control, Zhejiang University, Hangzhou 310027, China

Received May 11, 2011; revised June 4, 2012; accepted June 6, 2012

Abstract: The hydraulic excavator energy-saving research mainly embodies the following three measures: to improve the performance
of diesel engine and hydraulic component, to improve the hydraulic system, and to improve the power matching of diesel-hydraulic
system-actuator. Although the above measures have certain energy-saving effect, but because the hydraulic excavator load changes
frequently and fluctuates dramatically, so the diesel engine often works in high-speed and light load condition, and the fuel consumption
is higher. Therefore, in order to improve the economy of diesel engine in light load, and reduce the fuel consumption of hydraulic
excavator, energy management concept is proposed based on diesel engine cylinder deactivation technology. By comparing the universal
characteristic under diesel normal and deactivated cylinder condition, the mechanism that fuel consumption can be reduced significantly
by adopting cylinder deactivation technology under part of loads condition can be clarified. The simulation models for hydraulic system
and diesel engine are established by using AMESim software, and fuel combustion consumption by using
cylinder-deactivation-technology is studied through digital simulation approach. In this way, the zone of cylinder deactivation is
specified. The testing system for the excavator with this technology is set up based on simulated results, and the results show that the
diesel engine can still work at high efficiency with part of loads after adopting this technology; fuel consumption is dropped down to
11% and 13% under economic and heavy-load mode respectively under the condition of driving requirements. The research provides
references to the energy-saving study of the hydraulic excavators.

Key words: diesel engine, cylinder deactivation, hydraulic excavator, energy-saving

pump output and flow can adapt with maximum load

1 Introduction
The hydraulic excavator has the feature of high power,
high-fuel consumption. It plays an important role in
infra-structure engineering construction. The performance
of an excavator is directly related with construction costs
and environmental pollution. With the increases of
petroleum price in the world and national environmental
concerns, the energy-saving technology for hydraulic
excavator is now becoming a major direction to develop
and study[1–3].
At present, the main technologies for hydraulic excavator
energy-saving are as follows: (1) Constant power control.
This system can make full use of engine power without
causing diesel engine overload[4]; (2) Negative flow control,
which can help reduce power loss in bypass fuel return
circuit[5]; (3) Load-sensitive control system(LS), in which
* Corresponding author. E-mail: quanlong@tyut.edu.cn
This project is supported by National Hi-tech Research and
Development Program of China (863 Program, Grant No.
2010AA044401)
© Chinese Mechanical Engineering Society and Springer-Verlag Berlin Heidelberg 2012
requirement automatically, thus the efficiency and
controllability of actuators in dual arrangement working
medium system are improved[6]. In an excavator, however,
using power-matching scheme for the hydraulic system
alone is not enough, the performance of energy-saving is
not satisfied. Thus, in order to get high availability of
energy utilization, engine and hydraulic system should be
also matched. In Ref. [7], full power matching technology,
i.e., using load sensitivity system to achieve pump-load
matching and determine optimum working point, is studied.
Through automatic valve regulating of engine to set the
engine work near in optimal area, full-range power
maximum matching can be achieved and fuel consumption
can be reduced. On the other hand, due to frequent load
changes, significant lagging characteristic of engine
governing system and complicated configuration, the full
power matching technology is not so popular.
To improve further energy-saving effect for hydraulic
excavators, hybrid power system to the excavator has
become an important and new research direction. The
related researches show that, the hydraulic excavator adopts
parallel type hybrid power system can save energy by 10%
 ·898· YYANG Jing, et al: Excavator Energy-saving Efficiency Based on Diesel Engine Cylinder Deactivation TechnologyY
and above, at the same time, the installed power capacity
can be lowered[8–10]. Adversely, due to the extra
electromotor and the super capacitors, the hydraulic
excavator with hybrid power system has a high cost.
In order to improve economic performance, at the same
time maintain power drive demand and low cost, the new
concept of energy control based on deactivated diesel
engine cylinder technology for hydraulic excavator is
proposed. In this paper, based on working conditions, some
of cylinders are cut off from fuel supply to deactivate the
cylinders as load variation to obtain a higher load rate. In
this way, engine keeps track of load to make it work at
high-efficiency zone, reducing fuel consumption, reducing
emission, improving the economic performance of fuel
throughout working cycle.
2 Control Principle of Fuel-saving by
Deactivating Diesel Engine Cylinders
Fig. 1 shows the testing curve of output power vs. diesel
engine output torque in a working cycle of a hydraulic
excavator.
Fig. 1. Testing curve of output power vs. diesel engine
output torque
The analysis of the curves indicates that the
instantaneous power for the hydraulic pump is a big value
during working but the mean value of output power is
relatively small. Around 0–3 s, the arm goes down with
no-load, hydraulic pump output is very small, i.e.,
approximately 3 kW. Around 3–4 s, the excavator begins to
excavate, since the all the actuator are working, the pump
output power increases significantly. The peak value is 38
kW. During 4–7 s, the excavator begins to swing, in which
4–5 s are for motor rotation, pump output decreases to 12
kW. Then follows the combined rotation process, i.e., the
arm and bucket boom lift up as arm swings until the unload
position. In this duration, pump output is a big value, peak
value is 29 kW. During 7–8 s, the bucket opens, and then
the excavator is unloaded. The pump output power is small,
and its minimum value is 0.5 kW. During 8–12 s, the
excavator only swings. When the excavator begins to swing
or is being broken, the pump output power is higher, and
they are 22 kW and 17 kW respectively. In 12–16 s, the
excavator arm, bucket boom and stick lift up to the original
position and prepare for next action. Because more
actuators are working, pump output is a greater value, the
peak value 35 kW.
Similarly, in Fig. 1, we can see that, during a complete
working cycle, the load of the diesel engine fluctuates
violently. Since the diesel engine equipped for the
excavator works at rated speed (2 000 rmin), it will be at
high-speed and low-load condition while the arm dropping
down and rotating back with no-load, this will consume
more fuels[11].
Fig. 2 shows the universal characteristic curves of the
diesel engine employed for the excavator when all the
cylinders are working, which is tested through the testing
rack.
Fig. 2. Initial universal performance characteristic map
when all the cylinders are working (g(kW • h))
This is an equivalent curve of fuel consumption rate
drawn with engine speed n as x-axis and output torque T as
y-axis in Fig. 2, which can show the fuel economic
performance under different speed and load condition. In
Fig. 2, among these equal-fuel consumption curves, the
inner area of the innermost curve acts as economic zone. It
can be seen that from inner to outer, the fuel consumption
performance becomes higher and higher gradually, which
means the economic performance becomes poorer and
poorer. In Fig. 2, zone A is the working area of diesel
engine. Combined Fig. 1 with Fig. 2, it can be seen that
when an excavator is under low-load condition, the engine
is at low-load and high-speed condition, causing higher fuel
consumption as it is far away from engine’s economic zone.
In Fig. 1, within 0–3 s, the hydraulic excavator‘s arm goes
down, the diesel engine speed is 2 000 rmin, output torque
is less than 40 N • m. On the other hand, the corresponding
situation in Fig. 2 shows that, the fuel consumption is
greater than 320 g(kW • h)，by contrasting with 240
g(kW • h) at the lower part of zone A, fuel consumption
increases by 80 g(kW • h). On the basis of these data, we
can conclude that the most important thing to reduce diesel
fuel consumption is to improve the economic performance
under medium- and low-load condition, i.e., trying to allow
diesel engine run at or approximate to high-economic zone.
The electronic speed control system used in excavators
now can only reduce magnitude of speed fluctuation under
 CHINESE JOURNAL OF MECHANICAL ENGINEERING ·899·

a significant load change, it is unable to change work zone

under low-load condition in radical. Whereas, by using
engine cylinder deactivation technology to improve load
rate through deactivating a number of cylinders in low-load
condition[11]. This will help to let the engine work at or
close to high-efficiency zone and thus decrease fuel
consumption.
The foremost condition for applying this diesel engine
low-fuel consumption technology to an excavator is to
ensure its total power demand. Meanwhile, noise, vibration
and stability should be also considered. Since the vibration
for a four-cylinder engine is most serious when two of the
four cylinders are deactivated[12], which is approximate to
the vibrating case when an engine with one cylinder Fig. 4. Universal characteristics map after deactivating
deactivated at high speed[13–15], we use single-cylinder one cylinder (g(kW • h))
deactivation technology in this paper.
Fig. 3 shows the control principle on how to deactivate
cylinders of a diesel engine. Here, we can see that a 3 Power Drive System Structure
solenoid valve is used to control the fuel injector for No. 1 and Model Setup
cylinder of the diesel engine. When the fuel inlet port P of
this valve and fuel outlet port A is connected, the fuel To find out the essence of change of parameters in
supply from fuel injection pump to No. 1 fuel injector will hydraulic system of an excavator during working process,
be shut off. As a result, the fuel supply to the diesel optimize control strategy, the digital simulation model for
engine’s No. 1 cylinder is stopped, which causes it the whole power drive system is established firstly.
deactivated, thus the load rate of working cylinder is Fig. 5 is drive system structural diagram of a hydraulic
improved, and fuel consumption is reduced. When the fuel excavator by adopting cylinder deactivation technology.
The control unit analyzes movable arm displacement, stick
inlet port P of the valve and fuel outlet port B is connected,
displacement and bucket displacement, pressure in buckets
No. 1 cylinder will recover fuel supply and all the cylinders
and in chambers that connects with bucket linkage as well
for the diesel engine are working.
as motor outlet pressure to determine the current working
state of excavator, control solenoid valves to open/close in
predetermined control scheme.

Fig. 3. Diesel engine cylinder deactivation schematic

Fig. 4 shows the characteristic curve tested via testing
rack when No. 1 cylinder is deactivated. See to Fig. 1.
Similarly, within 0–3 s, the excavator’s arm is in
drop-down process, fuel consumption is less than 240
g(kW • h), which is close to high-performance zone
shown in Fig. 2. Thus, through cylinder deactivation
method, the load rate of working cylinders are improved,
causing it work in high-performance zone, which is good
for improvement of fuel economic performance of the
whole equipment.
Fig. 5. Schematic control diagram of whole equipment
On the basis of the components of the whole equipment
shown in Fig. 5, simulation model were set up, which
includes engine, hydraulic system, control unit subsystem
model, etc.
3.1 Engine subsystem models
As shown in Fig. 6, the excavator diesel Engine model is
established by using the IFP Engine model library in
 ·900· YYANG Jing, et al: Excavator Energy-saving Efficiency Based on Diesel Engine Cylinder Deactivation TechnologyY
AMESim software, fundamental performance parameters concluded from the chart above that hydraulic system
of diesel engine is shown in Table 1. simulation model can imitate practical systematic
performance in a better manner, enjoying relatively high
accuracy.

Fig. 6. Simulation model of the diesel engine

Table 1. Fundamental performance parameters

of diesel engine
Parameter Value
Diesel engine type 492
Four-strokes and Fig. 7. Simulation model for excavator hydraulic system
Pattern
non-turbocharged
Cylinder borestroke Φl(mmmm) 92100
Output volume VL 2.66
Compression ratio α 17.5
Ignition order 1-3-4-2
Nominal power P/kW 44
Rotational speed n((r • min–1) 2 400
The maximum torque T(N • m) 200 (1 800 rmin)

This model is the diesel engine model based on each

cylinder control. Considering the formation of mixture
gases in each cylinder, the differences among air intake,
Fig. 8. Pressure curve of the bucket
compression and combustion to do work, the model is
comprised of fuel supply, air distribution, energy
conversion and power output block. In the model of fuel
3.3 Control unit model
supply, due to the requirement of different working
By analyzing the above cylinder deactivation control of
conditions of the excavator, relevant cylinder fuel supply
hydraulic excavator and condition of the whole system, the
will be cut off, so the injection duration of each cylinder is
control strategy is determined, which should have met the
no longer the global variable, and the injection duration of
drive demand and economic requirements for the whole
each cylinder will be controlled by the control unit. The
system. In other words, the working demand for excavating
control unit will give the order to cut off the fuel supply of
must be sure without sacrificing working efficiency and
the cylinder when it is needed, then the cylinder injection
with less fuel consumption after the corresponding
duration is set to 0.
cylinders are deactivated.
The control strategy rules are as follows: When
3.2 Hydraulic subsystem model
excavator is in idle speed state (800 rmin), all the
Considering the fact that only the arm, stick, buckets and
cylinders must be deactivated to avoid low-speed
rotary part are in working in actual situation, thus, the
shaking[11]. When the arm goes down with no-load and
modes for these four subsystems and pump source are set
rotates back with no-load, engine cylinder deactivation
up (Fig. 7). When establishing these models, the real type
must be referred to. The hydraulic pump is of LUX series technology is used to reduce fuel consumption. Under other
A10VO63LRXDX Constant power load-sensitive axial conditions, all the cylinders must be activated.
plunger pump, and the hydraulic system is of independent
flow control with current anti-saturation theory, i.e., LUDV 4 Economy Simulation Results
system[16–17]. of the Power System
Fig. 8 shows the pressure comparison of hydraulic
system in excavator through simulation and test. It can be For economy and heavy-load condition, engine speed is
 CHINESE JOURNAL OF MECHANICAL ENGINEERING
2 000 rmin and 2 200 rmin respectively. Simulations are
performed under the conditions when all the cylinders are
working and just No. 1 cylinder of the diesel engineer is
deactivated
Fig. 9 shows the fuel consumption rate comparison curve
between the all-cylinder-activation and No. 1 cylinder
deactivation under economic mode and heavy load mode. A
drop in fuel consumption rate occurs when the diesel
engine is in the stage of cylinder deactivation, it can be
concluded that average fuel consumption rate can be
decreased in one working cycle by using engine cylinder
deactivation technology.
Fig. 9. Fuel consumption rate comparison curves
Fig. 10 shows the fuel consumption amount comparison
curve between the all-cylinder-working and No. 1 cylinder
deactivation under economic condition, among it, the
dotted line represents that the diesel engine is in cylinder
deactivation now.
Fig. 10. Fuel consumption comparison curves
under economic operating mode
·901·
From Fig. 10, it can be seen that the average amount of
fuel consumed drops to 11% in each working cycle after
use cylinder deactivation technology under economic
operating mode.
Fig. 11 is the fuel consumed amount comparison
between all-cylinder-activation and No. 1 cylinder
deactivation under heavy load condition, among it, the
dotted line represents that the diesel engine is in cylinder
deactivation now.
Fig. 11. Fuel consumption comparisons
under heavy load condition
From the curve in Fig. 11, it can be seen that an average
drop of fuel consumed amount for each cycle after using
cylinder deactivation technology is 13 %. Obviously, it has
a better effect than that of economic mode. This is because
the fact that the higher engine speed, the farther derivation
of partial load away from high-performance zone.
5 Test Research on Power and Economy
In order to survey the performance of energy-saving in
practical situation with cylinder deactivation scheme,
testing machine has been modified, i.e., it is equipped with
the sensor that can outputs displacement and speed
simultaneously, pressure sensors are amounted at pump
outlet, two chambers of hydraulic cylinder as well as fuel
inlet/outlet in the rotary mechanism, using Germany
dSPACE system to achieve signal acquisition and control.
Due to using cylinder deactivation technology, the fuel
supply system for the diesel engine for an excavator is
modified. Fig. 12 shows the fuel supply system after
modification. In which, a solenoid valve is provided
between No. 1 cylinder and high pressure fuel pump. This
makes it possible to shut off the fuel supply from high
pressure pump to No. 1 cylinder to deactivate it by
transmitting a command (signal) from dSPACE system to
trigger the valve. In this testing system, as high-speed
response solenoid valves are used, when valve disc travel is
100%, the response time is less than 20 ms, when engine
speed is 2 000 rmin, engine time lagging is 10–12 ms, the
response speed of the cylinder deactivation system is no
more than 35 ms. These parameters can completely meet
the practical working requirement for an excavator.
 ·902· YYANG Jing, et al: Excavator Energy-saving Efficiency Based on Diesel Engine Cylinder Deactivation TechnologyY

Fig. 12. Engine fuel shut-off device Fig. 13. Boom velocity cooperation curve
under heavy load mode

5.1 Testing method

To study the hydraulic excavator power and economy as
the diesel engine cylinder deactivation, we use the
following test methods.
(1) Select working mode and set the engine to preset
speed. The corresponding speed to heavy load and
economic mode is 2 200 rmin and 2 000 rmin,
respectively. Under the corresponding mode, allow the
excavator to run a standard working cycle with all the
cylinders activated and some of the cylinders deactivated Fig. 14. Boom pressure comparison curve
by fuel cut-off, respectively. under heavy load mode
(2) With the same original fuel quantity (0.5 L) and the 1. Rodless chamber (full cylinders working),
same test cycle index, the excavator is working in the 2. Rodless chamber (cylinder deactivation),
3. Rod chamber (full cylinders working),
heavy load mode and the economical mode separately. The 4. Rod chamber (cylinder deactivation).
dynamical performance and economical efficiency are
compared between all the cylinders are in working and one With the excavator working in the economic mode , on
of the cylinders is working in the cylinder deactivation the condition that all the engine cylinders are in working or
condition. one of the cylinders is adopting the cylinder deactivation
(3) When conducting contrast test, excavate the same method, the contrast curves of the boom velocity and the
subject in the identical place. Among them, apply soft soil boom cylinder pressure is shown in Fig. 15 and Fig. 16.
for the economic mode and relatively hard gravel soil for
the heavy load mode, and the excavators bucket is full.

5.2 Testing results

The experimental results from the excavator’s power and
economy are discussed as follows.
(1) Excavator drive performance. Some of the engine
cylinders are deactivated during the process when
excavator’s arm goes down, while, all the cylinders of the
engine are activated during the process when the movable
arm of the excavator lifts up. Therefore, in a complete
working cycle, we can analyze pressures in both chambers
of movable arm, speed of movable arm; compare state Fig. 15. Boom velocity cooperation curve
differences for two operating modes to identify whether it under economic mode
can affect power performance of whole system after
cylinder deactivation. According to the speed-contrast curves for the arm, all the
With the excavator working in the heavy load mode, and cylinders are working during moving arm lifting process
working in the economical mode on the condition that all regardless of economic or heavy load mode. Thus, the speed
the engine cylinders are in working or one of the cylinders change and peak values are nearly same. In moving arm
is adopting the cylinder deactivation method, the contrast down process (speed less than zero), the diesel engine torque
curves of the boom velocity and the boom cylinder pressure output is low. So, the power output can completely meet the
is shown in Fig. 13 and Fig. 14. load demand after cylinder deactivation. For this reason,
 CHINESE JOURNAL OF MECHANICAL ENGINEERING
speed change and peak values after deactivating the cylinders
are close to those of the real machine.
Fig. 16. Boom pressure comparison curve
under economic mode
1. Rodless chamber (full cylinders working),
2. Rodless chamber (cylinder deactivation),
3. Rod chamber (full cylinders working),
4. Rod chamber (cylinder deactivation).
According to pressure comparison curves, no matter
under economic or heavy load condition, pressure change
in the chambers of cylinders to drive the arm and difference
values in both chambers are close to that of
All-Cylinder-Working state. This indicates that the arm still
does the same work after the cylinders are deactivated.
(2) Economic performance of excavator. When fuel
amount is 0.5 L, after the same number of working
cycle—19 under heavy-load condition, the diesel fuel for
an given excavator will be used up for
all-cylinder-activation scheme. While for cylinder-
deactivation scheme, the fuel still remains 80 mL.
As shown in Fig. 17(a). Considering the factor of the
residual fuel amount diesel in fuel supply system, the fuel
saved is 13%, this result is very close to the simulation
result. For a given diesel engine under economic operating
mode, suppose the diesel fuel amount is 0.5 L, let’s see the
difference. When all the cylinders are working, the fuel will
be used up after 23 of working cycles. However, for the
situation that engine-cylinder-deactivation technology is
used, the diesel fuel still remains 60 mL after the same
number of working cycles. As shown in Fig. 17(b). Thus,
the mount of diesel fuel saved is 11%.
(a) Heavy-load mode (b) Economical mode
Fig. 17. Fuel saving quality when the cylinder
deactivation system is adopted
·903·
6 Conclusions
(1) Selecting the proper cylinder-deactivation zone can
meet the original power drive demand.
(2) Using high-speed solenoid valve can achieve fuel
supply control for corresponding engine cylinder. This can
avoid involvement of flywheel into the electronic speed
regulation system, because it has a greater inertia property.
Thus, fast response is obtained in the system.
(3) Using engine cylinder deactivation technology can
reduce fuel consumption by about 11% under economic
mode, about 13% under heavy load condition.
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Biographical notes
YANG Jing, born in 1972, is currently a PhD candidate at Institute
of Mechatronics Engineering, Taiyuan University of Technology,
China. His research interests include dynamic analysis of
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mechanical engineering and energy-saving technology.
Tel: +86-13754863922; E-mail: yjing-000@163.com
QUAN Long, born in 1959, is currently a professor and a PhD
candidate supervisor at Institute of Mechatronics Engineering,
Taiyuan University of Technology, China. His research interests
include mechatronics engineering, fluid power transmission and
control.
Tel: +86-351-6014956; E-mail: quanlong@tyut.edu.cn
YANG Yang, born in 1984, is currently a master candidate at
Institute of Mechatronics Engineering, Taiyuan University of
Technology, China.
E-mail: readyyang_wonder@163.com