ANALYSIS OF POSSIBILITY OF ADAPTATION 
REGENERATION CONCEPT FOR ENGINE DRIVEN 
EMPTY CONTAINER HANDLERS 
W. L. L. Wickramarachchi 
(8432) 
Degree of Master of Science 
University of Moratuwa 
102534 
Department of Electrical Engineering 
University of Moratuwa 
Sri Lanka 
December 2011 
102534 
ANALYSIS OF POSSIBILITY OF ADAPTATION 
REGENERATION CONCEPT FOR ENGINE DRIVEN 
EMPTY CONTAINER HANDLERS 
W. L. L. Wickramarachchi 
(8432) 
Dissertation submitted in partial fulfilment of the requirements for the 
Degree of Master of Science 
Department of Electrical Engineering 
University of Moratuwa 
Sri Lanka 
December 2011 
DECLARATION 
I declare that this is my own work and this dissertation doesn't incorporate 
without acknowledgement any material previously submitted for a Degree 
or Diploma in any other University or institute of higher learning and to the 
best of my knowledge and belief it doesn't contain any material previously 
published or written by another person except where the acknowledgement 
is made in the text. 
Also, I hereby grant to University of Moratuwa the non-exclusive right to 
reproduce and distribute my dissertation, in whole or in part in print, 
electronic or other medium. I retain the right to use this content in whole or 
such as articles or books) 
16 t n December, 2011 
The above candidate has carried out research for the Masters Dissertation 
under our supervision. 
Dr. A.M. Harsha. S. Abeykoon 
Dr. V.P.C. Dasanayake 
iii 
ABSTRACT 
Empty container handling operations in inland container depots is a major economic 
and environmental problem today due to fossil fuel burning. This research examines 
reuse of braking and reverse energy to reduce fuel cost and environmental impact. 
The research was originated within the domain of electrical regeneration means as 
most of the known regeneration applications are electrical energy related. However 
regeneration by means of hydraulic energy was selected as Linde-II, base- equipment 
to the research is hydraulic based. 
One major innovative step taken in this project is application of discharge pressure of 
the accumulator to suction side of the gear pump. This is a novel concept which have 
not patented yet anywhere in the world. The energy saving potential of the proposed 
reengineering solution is estimated to be 33%. Saving potential of the solution is 
substantial and lucrative. Simulation results were used to validate the reengineering 
solution in terms of power reduction. Actual fuel consumption of the proposed 
solution may defend on the way engine is controlled. Simplicity and low capital cost 
are two positive aspects of the solution. Even though the saving potential was 
impressive, it could not be implemented into a prototype mainly due to non 
availability of suitable gear pumps. Therefore solution is limited to a concept for this 
moment. 
It is essential to have a positive engine control with respect to accumulator action in 
order to obtain optimum possible fuel savings. Whilst the accumulator is charging 
and discharging, there is an effect on lifting and lowering speeds. Variations in 
lowering and lifting speeds due to the proposed solution could affect performance 
related to the users' needs, however it has not been considered within the scope of 
the research. Main research areas precede parallel to this study are: recovery of 
braking energy, development of an engine control algorithm, a study on variations of 
lifting and lowering speed, and a reliability assessment of the proposed reengineering 
solution. 
This concept is novel and can be defined as a green supply chain initiative in which 
outcomes lead to a reduction of green house gas emissions, and also to reduce carbon 
footprint in the shipping industry. 
iv 
ACKNOWLEDGEMENT 
It is with deep gratitude I acknowledge the generous assistance, kind and valuable 
guidance of my supervisors Dr. Harsha Abeykoon of Department of Electrical 
Engineering and Dr. Palitha Dasanayake of Department of Mechanical Engineering 
University of Moratuwa in completing this study successfully. 
I also wish to extend my sincere thanks to all the lecturers who thought me valuable 
lessons throughout the Master of Science course and all others at University of 
Moratuwa for their contributions and friendly support in the course of the study. 
Further, I wish to extend my warm gratitude and thanks to the management and my 
engineering staff at Aitkenspence Logistics, who helped me to develop the 
reengineering solution for Linde-II, Empty Container Handler. 
I specially thank my wife Dr. Dinusha Dahanayake and my parents for encouraging 
me towards successful completion of this research study. 
Last but not the least I am grateful to Mr. Lilintha Lakmal and Mr. Amila 
Amarathunga of University of Moratuwa who lavishly shared their knowledge and 
expertise to simulate and analyze the solution and for all others who helped me in 
their own special way without which this would not have been a success. 
TABLE OF CONTENTS 
Declaration iii 
Abstract iv 
Acknowledement v 
Table of contents vi 
List of figures xii 
List of tables xiv 
List of abbreviations xv 
1 Introduction 1 
1.1 Overview 1 
1.2 Empty container logistics operation 1 
1.2.1 Container terminals 2 
1.3 Energy embedded in container stack 2 
1.4 Regeneration in the context of container handling 3 
1.5 Outline 4 
1.6 Container handling systems 5 
1.6.1 Container crane 5 
1.6.2 Rubber tyred gantry crane 5 
1.6.3 Straddle carrier 6 
1.6.4 Reach stacker 6 
1.6.5 Mast mounted empty container handlers 6 
1.7 Background 9 
1.8 Limitations 9 
1.9 Literature survey 9 
1.10 Conceptual frame work 10 
1.11 Methodology 10 
1.12 Motivation 11 
2 Problem statment 13 
2.1 Introduction 13 
2.2 Identification of the problem 13 
vi 
2.3 Environmental and human impact 13 
2.4 Impact of the oil price 15 
2.5 Low fuel quality 15 
2.6 Nature of the business 15 
2.7 Application of regeneration concept for empty container handlers 15 
2.8 Why this research is significant 16 
2.9 Objective of the study 16 
2.10 Importance of the study 17 
2.11 Summary 18 
3 Basics of Engining driven mast mounted empty container handlers 19 
3.1 Introduction 19 
3.2 Overview of the base-equipment 19 
3.3 Identification of main systems of the base-equipment 20 
3.3.1 Engine : 20 
3.3.2 Transmission unit 21 
3.3.3 Drive axle 21 
3.3.4 Rear axle of the truck 22 
3.3.5 Hydraulic system 22 
3.3.6 Main components of the lifting system 26 
3.3.7 Directional Control Valves 29 
3.3.8 Steering priority valve (E) 29 
3.3.9 Locking blocks (J) 30 
3.3.10 Main hydraulic pumps 30 
4 Literature survey - I 31 
4.1 Introduction 31 
4.2 Electrical Vehicles 31 
4.2.1 Would electrification of equipment be viable option? 31 
4.2.2 Evolution of the concept of electrical vehicle 32 
4.2.3 Battery electric vehicles 32 
4.2.4 Engine powered electric vehicles 33 
4.3 Hybrid vehicles 33 
vii 
4.4 Use of fly wheels and capacitors for energy storage 35 
4.5 Hybrid hydraulic 36 
4.5.1 Hybrid drives in off-highway applications 38 
4.6 Regenerative braking with hydraulic bladder accumulators 39 
4.7 Hydrid concept 41 
4.7.1 Main components of the Hydrid system 42 
4.7.2 Delivering cycle analysis of the hydrid system 43 
4.7.3 Fuel consumption 44 
4.8 Summary 47 
5 Litrature survey - II 48 
5.1 Introduction 48 
5.2 Basics of hydraulics 48 
5.2.1 Continuity Equation 48 
5.2.2 Reynolds Number 49 
5.2.3 Relationship for motion of liquid along a stream line 50 
5.2.4 Energy Losses 51 
5.3 Hydraulic components 53 
5.3.1 Rotary gear pump 53 
5.3.2 Directional control Valves 54 
5.3.3 Shuttle valve 55 
5.3.4 Pressure control valves 55 
5.3.5 Pressure reducing valves 56 
5.3.6 Accumulators 56 
5.3.7 Selection of Bladder Accumulators 61 
5.3.8 Bladder Accumulator Sizing 61 
5.4 Analysis of lifting circuit of working hydraulic system of Linde-II, 65 
5.4.1 No function, directional control valves are set in neutral 65 
5.4.2 Lifting Function 67 
5.4.3 Lowering Function 68 
5.5 Summary 69 
6 Conceptual framework 71 
viii 
w 6.1 Introduction 71 
6.2 Energy flow 71 
6.3 Reuse of braking energy of the equipment 72 
6.4 Possible ways of storing of energy 73 
6.5 Possible ways of capturing of energy 74 
6.6 Illustration of possibilities and solutions 74 
6.7 First Concept based on electrical energy 77 
6.7.1 First candidate solutions of the first concept 78 
6.7.2 Second candidate solutions of thee first concept 78 
6.8 Second concept based on hydraulic energy 79 
6.8.1 Analysis of the first concept 80 
6.8.2 Analysis of the second concept 81 
6.9 Evaluation of concepts 83 
6.10 Development of decision matrix 86 
6.11 Summary 88 
7 Methodology 90 
J
 7.1 Introduction 90 
7.2 Conceptual frame work 90 
7.3 User Needs 91 
7.4 Engineers Perspectives 91 
7.5 Identifying Alternatives 92 
7.6 Development of hydraulic circuits 93 
7.6.1 Problems 94 
7.6.2 Evaluation of Alternatives 95 
7.7 Development of alternative circuit 95 
7.7.1 Sub problems and limitation 97 
8 Solution analysis 99 
8.1 Introduction 99 
8.2 Problem Definition 99 
8.3 Calculation 99 
8.3.1 Actual System 100 
ix 
8.3.1.2 Calculating the discharge pressure of the pump 101 
8.3.2 Calculation of the pump power 103 
8.3.3 Proposed system 105 
8.3.4 Energy Saving 109 
8.4 Summary 110 
9 Modeling 112 
9.1 Introduction 112 
9.2 Rearranging the existing circuit 112 
9.3 Modeling 113 
9.3.1 Limitations and importance of modeling 114 
9.3.2 Available modeling software 114 
9.4 Modeling of existing circuit 116 
9.5 Assumptions, Simplifications and System parameters 118 
9.6 Plotting of results 119 
9.6.1 Simulation of pump torque and shaft velocity of the pump 119 
9.6.2 Simulation of lifting and lowering speeds of Linde-II 122 
9.6.3 Determination of pressures 123 
9.7 Modeling of proposed reengineering solution 124 
9.8 Comparison of simulation results 128 
10 Conclusion 130 
10.1 General Overview 130 
10.2 Problems encountered in reengineering of Linde-II 130 
10.3 Innovative approach 131 
10.4 Outcome of the reengineering solution 131 
10.5 Future study and 1 imitations 132 
10.5.1 Engine control algorithm for the solution 133 
10.5.2 Lifting and lowering speed controlling algorithm 133 
10.5.3 Assessment of reliability and safety of the equipment 134 
10.5.4 Pump development 134 
10.6 Drawbacks of the reengineering solution 135 
10.7 Achievements and Positive Aspects 135 
x 
v References 137 
A Appendix A 140 
A.l Electrical motors 140 
A. 1.1 Controlling of the motors 141 
A.2 Types of Motors 141 
A.3 DC motor efficiency 142 
A.4 Motor losses and motor size 143 
A.5 Tapping braking energy of electric motors 144 
A.6 Limitation of DC brushed motors 145 
A.7 Brushless DC motors 145 
A.8 Switched reluctance motors 146 
A. 9 The induction motor 147 
A. 10 Ways of improving motor efficiency 148 
A. 11 Motor mass 148 
A. 12 Selection of electrical machines for hybrid applications 149 
A. 12.1 Use of battery as a source of energy 150 
* A. 12.2 Energy in a capacitor 151 
B Appendix B 152 
B.l Engine Performance Curves 152 
B.l. l 20 ft Containers 153 
B.1.2 40ft 157 
B.l.3 Reefer 160 
xi 
LIST OF FIGURES 
Page 
Figure 3.1: LINDE C80/6 Empty Container Handler [17] 19 
Figure 3.2: Power flow components of the equipment [17] 20 
Figure 3.3: Power transmission unit [17] 21 
Figure 3.4: Steering axle [17] 22 
Figure 3.5 : Simplified schematic diagram of the hydraulic system 23 
Figure 3.6 : Lift cylinders [17] 27 
Figure 3.7: Exploded view of the mast [17] 28 
Figure 3.8: Spreader [17] 28 
Figure 3.9: Directional Control Valves [17] 29 
Figure 3.10: Steering priority valve [17] 30 
Figure 4.1: Rechargeable battery electric vehicle [11] 33 
Figure 4.2: Series hybrid vehicle layout [11] 34 
Figure 4.3: Parallel hybrid vehicle layout [11] 35 
Figure 4.4: Hybrid hydraulic layout; source: Eaton Hydraulics [22] 37 
Figure 4.5: Commercial application of hydraulic hybrid [22] 37 
Figure 4.6: Volvo L220F Hybrid wheel loader [25] 39 
Figure 4.7: Rexroth hydrostatic regenerative braking system [29] 40 
Figure 4.8: Fuel cell hybrid fork lift [28] 40 
Figure 4.9: Comparison of electric and hydraulic hybrid systems [29] 41 
Figure 4.10: Main components of hydrid system [29] 43 
Figure 4.11: Comparison of energy balance of conventional and hydrid system [29] 
44 
Figure 4.12: Comparison of fuel consumption [29] 45 
Figure 4.13: Efficiency map for the engine [29] 45 
Figure 4.14: Comparison of C02 emissions at NEDC [29] 46 
Figure 5.1: Moody Chart [32] 52 
Figure 5.2: Bladder Accumulator Sizing [34] 62 
Figure 5.3: Correction factors for change of state [34] 64 
Figure 6.1: Energy flow across the lifting system 71 
Figure 6.2: Block diagram of the energy flow across the system 72 
Figure 6.3: Elements of first concept, first sub candidate solutions 77 
Figure 6.4: Elements of first concept, second sub candidate solution 78 
Figure 6.5: Elements of second concept, first sub candidate solution 79 
Figure 6.6: Elements of second concept, second sub candidate solution 80 
Figure 6.7: Block presentation of energy flow of first concept 81 
Figure 6.8: Block presentation of energy flow of second concept 82 
Figure 7.1: First candidate hydraulic circuit 94 
Figure 7.2: Alternative hydraulic circuit 96 
Figure 8.1: Lifting mechanism of Linde-II 100 
Figure 8.2: Engine plot for lifting of 20ft empty container 104 
Figure 8.3: Proposed hydraulic circuit for lifting system 105 
Figure 8.4: Bladder Accumulator Sizing [34] 107 
Figure 8.5: Correction factors for adiabatic change of state [34] 109 
Figure A.l : Torque/ Speed graph for a brushed DC motor [21] 140 
Figure A.2: Graph of data from a real 250 kW fuel cell used for a bus 145 
Figure A.3: Typical torque/ speed curve for an induction motor [21] 147 
Figure A.4:- Specific powers of electric motors [11] 149 
Figure B.l: Test results for lowering of 20ft container 153 
Figure B.2 : Test results for lifting attempt top of 20ft container 153 
Figure B.3: Test results for lifting beginning of 20ft container 154 
Figure B.4: Test results for while lifting of 20ft container 154 
Figure B.5: Test results for while lifting of 20ft container 155 
Figure B.6 : Test results of beginning of lifting of the second 20ft container 156 
Figure B.7: Test results for lowering of 40ft container 157 
Figure B.8: Test results of beginning of lifting of 40ft container 157 
Figure B.9 : Test results for while lifting of 40ft container 158 
Figure B. 10: Test results for while lifting of 40ft container 158 
Figure B.l 1: Test results for lift stop of 40ft container 159 
Figure B.12: Test results for lowering of Reefer container 160 
Figure B.13: Test results for lowering from the top position of Reefer container ..161 
Figure B.14: Test results for while lifting of Reefer container
 ; 162 
Figure B.l 5: Test results for beginning of lifting of Reefer container 163 
Figure B.16: Test results for beginning of lifting of second Reefer container 164 
Figure B.l 7: Test results for beginning of lifting of second Reefer container 164 
Figure B.l 8: Test results for while lifting of second Reefer container 165 
Figure B.l 9: Test results for beginning of lifting of second Reefer container 166 
xiii 
LIST OF TABLES 
, Page 
xiv 
Table 2: Emission Growth [8] 12 
Table 3: Possibility -Solution Matrix 75 
Table 4: Solution matrix 76 
Table 5: Concept evaluation 84 
Table 6: Decision matrix 87 
Table 7: Comparison of various types of batteries [16] 151 
LIST OF ABBREVIATIONS 
Abbreviation 
ACM 
BLDC 
CO 
C 0 2 
CRPS 
CVT 
DC 
ECH 
ECM 
ECM 
GSC 
HBRS 
HLA 
ICE 
IFAS 
IVT 
NEDC 
N 2 0 
PM 
RS 
RTG 
SR 
Description 
Alternative Current Motor 
Brushless DC motor 
Carbon Monoxide 
Carbon Dioxide 
Common Pressure Rail system 
Continuous Variable Transmission 
Direct Current Motors 
Empty Container Handlers 
Engine Control Module 
Electronically Commutated Motor 
Green Supply Chains 
Hydrostatic Regenerative Braking System 
Hydraulic Launch Assist 
Internal Combustion Engines 
German Institute for Fluid Power Drives and Controls 
Infinitely Variable Transmission 
New European Drive Cycle 
Nitrous Oxides 
Particulate Matter 
Reach Stackers 
Rubber Tyred Gantries 
Switched Reluctance 
xv 
Straddle Carriers 
Ship to Shore Cranes 
Twenty feet Equivalent Units 
Volatile Organic Compounds