Thermodynamic Simulation Analysis and Optimization Design of Potato Harvester Hydraulic System for Hilly–Mountainous Areas

Potato harvesters operating in hilly and mountainous areas are often subjected to harsh working conditions such as high temperature, sun exposure, and high torque excavation. Due to the fluid sealing characteristics, closed loop hydraulic systems are prone to high temperatures during long-term continuous operation, resulting in a decrease in fluid viscosity, poor lubrication, severe wear, and power attenuation. This study investigates the hydraulic system of potato harvesters in hilly terrain, systematically analyzing its energy transfer process and identifying key heat-generating components. Based on an optimization strategy that extends the flow path of high-temperature fluid within the tank, four distinct tank designs were proposed. Computational fluid dynamics (CFD) and thermodynamic simulations were conducted to evaluate their heat dissipation performance, followed by full-machine validation testing. Results indicate that the walking and lifting systems are the primary heat sources. The dual pump contributes the highest proportion of heat (52.07%), followed by the walking motor (20.54%). The heat exchanger dissipates 72.91% of the heat, while the hydraulic oil tank accounts for 14.93%. Among the four tank designs, Tank 0 exhibited the fastest temperature rise, reaching a thermal equilibrium of 83.27 &deg:C, whereas Tank 1 had the lowest equilibrium temperature (78.62 &deg:C). Heat dissipation efficiencies for the tanks were 7.8%, 12.9%, 10.1%, and 11.6%, respectively. The residual gas volume fraction decreases significantly as the bubble diameter increases, due to the higher buoyancy and faster rise velocity of larger bubbles, which leads to shorter residence times and more effective precipitation. Tank 1 achieved the lowest equilibrium temperature, indicating the best thermal efficiency. Tank 3 showed the best overall degassing performance, particularly for medium-to-large bubbles. Tank 1 was selected as the optimal final design because it could offer an excellent balance, with very good cooling and competitive degassing (especially for small bubbles). Field tests confirmed a 14.8% reduction in thermal equilibrium temperature for Tank 1 (75.6 &deg:C) compared to Tank 0 (88.7 &deg:C). Simulation and experimental data showed strong agreement, with maximum errors of 9.2% for return fluid temperature, 12.7% for cooling return fluid temperature, 9.7% for pressure, and 8.5% for flow rate. Average errors remained below 8.4% for pressure and 7.6% for flow rate. These results validate the accuracy of the simulation model and the effectiveness of the tank optimization method.