Volume 1 – Symposium: Tuesday, March 8

Group A: Digital Hydraulics Group B: Intelligent Control Group C: Valves Group D | G | K: Fundamentals Group E | H | L: Mobile Hydraulics Group F | I: Pumps Group M: Hydraulic Components:Group A: Digital Hydraulics Group B: Intelligent Control Group C: Valves Group D | G | K: Fundamentals Group E | H | L: Mobile Hydraulics Group F | I: Pumps Group M: Hydraulic Component

Vibration and control research of pipe penetration piece

The concealment capability of submarine is seriously restricted by the vibration of pipe penetration piece which is an important obstacle to the development of ‘quiet submarine’. In this paper, the characteristics and structures of pipe penetration piece are analyzed. Combining with domestic and foreign achievements, the active and passive methods of piping vibration reduction were introduced, and the measures of piping vibration isolation were elaborated. It provides reference for the vibration control of pipe penetration piece

Volume 3 – Conference

We are pleased to present the conference proceedings for the 12th edition of the International Fluid Power Conference (IFK). The IFK is one of the world’s most significant scientific conferences on fluid power control technology and systems. It offers a common platform for the presentation and discussion of trends and innovations to manufacturers, users and scientists. The Chair of Fluid-Mechatronic Systems at the TU Dresden is organizing and hosting the IFK for the sixth time. Supporting hosts are the Fluid Power Association of the German Engineering Federation (VDMA), Dresdner Verein zur Förderung der Fluidtechnik e. V. (DVF) and GWT-TUD GmbH. The organization and the conference location alternates every two years between the Chair of Fluid-Mechatronic Systems in Dresden and the Institute for Fluid Power Drives and Systems in Aachen. The symposium on the first day is dedicated to presentations focused on methodology and fundamental research. The two following conference days offer a wide variety of application and technology orientated papers about the latest state of the art in fluid power. It is this combination that makes the IFK a unique and excellent forum for the exchange of academic research and industrial application experience. A simultaneously ongoing exhibition offers the possibility to get product information and to have individual talks with manufacturers. The theme of the 12th IFK is “Fluid Power – Future Technology”, covering topics that enable the development of 5G-ready, cost-efficient and demand-driven structures, as well as individual decentralized drives. Another topic is the real-time data exchange that allows the application of numerous predictive maintenance strategies, which will significantly increase the availability of fluid power systems and their elements and ensure their improved lifetime performance. We create an atmosphere for casual exchange by offering a vast frame and cultural program. This includes a get-together, a conference banquet, laboratory festivities and some physical activities such as jogging in Dresden’s old town.:Group 8: Pneumatics Group 9 | 11: Mobile applications Group 10: Special domains Group 12: Novel system architectures Group 13 | 15: Actuators & sensors Group 14: Safety & reliabilit

Investigation of Novel Displacement-Controlled Hydraulic Architectures for Railway Construction and Maintenance Machines

This dissertation aims at showing how to transform hydraulic systems of railway multi-actuator machinery characterized by inefficient state-of-the-art systems into the 21st Century. Designing machines that are highly efficient, productive, reliable, and cost affordable represents the target of this research. In this regard, migrating from valve-controlled architectures to displacement-controlled layouts is the proper answer. Displacement-controlled systems remove the losses generated by flow throttling typical of conventional circuits, allow an easy implementation of energy recovery (e.g. during regenerative braking), and create the possibility for the use of hybrid systems capable of maximizing the downsizing of the combustion engine. One portion of the dissertation focuses on efficient propulsion systems suitable for railway construction and maintenance machines. Two non-hybrid architectures are first proposed, i.e. a novel layout grounded on two independent hydrostatic transmissions (HSTs) and two secondary controlled hydraulic motors (SCHMs) connected in parallel. Three suitable control strategies are developed according to the specific requirements for railway machines and dedicated controllers are implemented. Detailed analyses are conducted via high-fidelity virtual simulations involving accurate modeling of the rail/wheel interface. The performance of the propulsion systems is proven by acceptable velocity tracking, accurate stopping position, achieving regenerative braking, and the expected behavior of the slip coefficients on both axles. Energy efficiency is the main emphasis during representative working cycles, which shows that the independent HSTs are more efficient. They consume 6.6% less energy than the SCHMs working with variable-pressure and 12.8% less energy than the SCHMs controlled with constant-pressure. Additionally, two alternative hybrid propulsion systems are proposed and investigated. These architectures enable a 35% reduction of the baseline machine’s rated engine power without modifying the working hydraulics. Concerning the working hydraulics, the focus is to extend displacement-controlled technology to specific functions on railway construction and maintenance machines. Two specific examples of complete hydraulic circuits for the next generation tamper-liners are proposed. In particular, an innovative approach used to drive displacement-controlled dual function squeeze actuators is presented, implemented, and experimentally validated. This approach combines two functions into a unique actuator, namely squeezing the ballast and vibrating the tamping tools of the work-heads. This results in many advantages, such as variable amplitude and variable frequency of the tamping tools’ vibration, improved reliability of the tamping process, and energy efficient actuation. A motion of the squeeze actuator characterized by a vibration up to 45 Hz, i.e. the frequency used in state-of-the-art systems, is experimentally confirmed. In conclusion, this dissertation demonstrates that displacement-controlled actuation represents the correct solution for next-generation railway construction and maintenance machines

Digitaalihydraulisen monipainejärjestelmän hyötysuhteen määrittäminen kuormaa nostaviin sovelluksiin

The purpose of this thesis is to determine the energy efficiency of the digital hydraulic multi-pressure actuator (DHMPA) for use in load-lifting applications. In order to accomplish this, three different characteristic efficiencies are defined; traditional, total, and regeneration efficiency. The traditional efficiency represents a comparable figure to that in traditional hydraulic systems. However, it does not consider energy regeneration, and thus, does not reflect the true efficiency of the DHMPA. Therefore, the total efficiency considering the regeneration, is defined. Furthermore, the regeneration efficiency describes how efficiently load-mass potential energy can be restored to the system. In addition, novel digital hydraulic technologies are reviewed and the operation of the DHMPA unit is studied. The efficiency figures are determined based on experimental measurement results. The test setup consists of pump unit, load-lifting test rig and the DHMPA. Measurements are done with a separate data acquisition system and the data acquired is analysed in MATLAB. Measured quantities are pressures, flow rates, positions, and temperatures of the system during the 500-cycle lifting-lowering test of the 1180 kg load-mass. The collected data is used for calculating the energy balance of the system, which can then be used for determining the three characteristic efficiencies of the system. In addition, the system performance is evaluated based on this data. The results show that the DHMPA is feasible for use in load-lifting applications. However, some unexpected errors occurred in the positioning of the load-mass. Nevertheless, the performance can be improved by careful tuning and dimensioning of the DHMPA components. Although the system performance requires further investigation, the energy-efficiency is highly competitive to that of conventional hydraulic systems. The traditional efficiency was 128%, yielding approximately 3-4 times lower energy consumption than the traditional systems. The total efficiency exceeded 63%, which is remarkably higher than that of traditional systems. Furthermore, the potential energy from the load-mass could be regenerated with efficiency of 80%. Therefore, this study showed that the DHMPA has a significant energy-saving potential in load-lifting applications. However, in order to optimize the system performance and efficiency, a further study will be needed.Tämän diplomityön tarkoituksena on määrittää digitaalihydraulisen monipainejärjestelmän (DHMPA) hyötysuhde kuormaa nostavia sovelluksia varten. Tämän tavoitteen saavuttamiseksi, kolme ominaista hyötysuhdelukua määritetään: perinteinen, kokonais- ja talteenottohyötysuhde. Perinteinen hyötysuhde antaa vertailukelpoisen luvun perinteisten hydraulijärjestelmien kanssa. Se ei kuitenkaan ota huomioon talteenotettua energiaa, eikä siten kuvasta järjestelmän todellista hyötysuhdetta. Tämän vuoksi määritetään kokonaishyötysuhde, joka huomioi energian talteenoton. Talteenottohyötysuhde puolestaan kuvaa, kuinka tehokkaasti massan nostoon sidottu potentiaalienergia voidaan ottaa takaisin järjestelmään. Lisäksi esitellään muita uusia digitaalihydrauliikan sovelluksia sekä perehdytään tarkemmin DHMPA:n toimintaan. Hyötysuhdeluvut määritetään kokeellisten mittaustulosten avulla. Testijärjestelmä koostuu hydraulikoneikosta, massaa nostavasta testipenkistä sekä DHMPA-yksiköstä. Mittausdata kerätään erillisellä tiedonkeruujärjestelmällä ja se analysoidaan MATLAB-ohjelmistolla. Mitattavia suureita ovat järjestelmän paineet, tilavuusvirrat, asemat sekä lämpötilat 500-askelisen, 1180 kg:n massaa nostavan ja laskevan testiohjelman aikana. Näiden tietojen avulla määritetään järjestelmän energiatase, josta puolestaan voidaan johtaa halutut hyötysuhdeluvut. Lisäksi näiden tietojen avulla voidaan arvioida järjestelmän toimintaa ja suorituskykyä. Tulokset näyttävät, että DHMPA-yksikköä voidaan soveltaa kuormaa nostavissa sovelluksissa. Testiajon aikana esiintyi kuitenkin odottamattomia asemavirheitä. Näitä virheitä voidaan minimoida virittämällä ja mitoittamalla järjestelmä huolellisesti. Vaikka tämä vaatiikin lisätutkimusta, voidaan todeta, että DHMPA:n hyötysuhde on hyvin kilpailukykyinen perinteisiin järjestelmiin verrattuna. Perinteinen hyötysuhde oli 128%, mikä tarkoittaa noin 3-4 kertaa pienempää energian kulutusta tavanomaisiin järjestelmiin verrattuna. Kokonaishyötysuhteeksi saatiin yli 63%, joka on merkittävästi parempi kuin perinteisten järjestelmien. Massan potentiaalienergia kyettiin ottamaan talteen 80% hyötysuhteella. Tutkimuksen avulla osoitettiin, että DHMPA voi tarjota huomattavan energiansäästöpotentiaalin massaa nostaviin järjestelmiin. Lisätutkimusta kuitenkin tarvitaan suorituskyvyn ja hyötysuhteen optimoimiseksi

Conception, modelling and dimensioning of an energy storage system for wind energy with hydro accumulators

Humankind currently faces an unstoppably increasing energy demand and scarcity of resources. The associated problems of climate change and global warming have intensified the role of renewable energies, especially of wind energy, in today’s energy supply. However, a critical disadvantage of renewables is their intermittent availability, which complicates the reliability of supply. As a result, energy storage technologies have become more and more important in recent times to overcome periods, when renewables do not provide power to the electrical grid. Among the various storage methods, a research team at the University of Applied Sciences of Saarland focuses on a particularly sustainable and environmentally friendly storage solution: The decentralised storage of excess wind energy with pressurised air. Here, purely pneumatic (i.e. compressed air energy storage, CAES) and hydraulic-pneumatic storage systems are considered simultaneously. Both systems are designed, dimensioned and modelled in separate scientific studies for the research project by ensuring comparability. This work deals with the hydraulic-pneumatic approach whereby hydro accumulators are utilised to store the surplus energy. Within the research scope, important theoretical and physical basics are illustrated for the storage concept. A first approach is provided for the dimensioning of the hydro accumulator system, which can serve as a starting point for the design of a prototype. For the dimensioned storage system, several basic models are created and simulated for evaluation and comparison purposes with the software tool AMESim. The simulation results are consistent with the outcome of the dimensioning and allow first statements about the system’s efficiency and performance. The comparison with the purely pneumatic system shows that achievable energy densities of hydraulic accumulators are much lower. However, CAES systems have to challenge comparably high thermal losses during the storage process. Hydraulic accumulators are therefore most likely to achieve better efficiencies, which CAES systems could only achieve by laboriously reusing the waste heat. At the current research stage, more precise statements cannot be made, since idealised conditions have been assumed for initial simulations. For this reason, the scientific paper is structured in a way that the research team can use the provided models and collected data as a foundation for further investigations and optimisations

Volume 2 – Conference

We are pleased to present the conference proceedings for the 12th edition of the International Fluid Power Conference (IFK). The IFK is one of the world’s most significant scientific conferences on fluid power control technology and systems. It offers a common platform for the presentation and discussion of trends and innovations to manufacturers, users and scientists. The Chair of Fluid-Mechatronic Systems at the TU Dresden is organizing and hosting the IFK for the sixth time. Supporting hosts are the Fluid Power Association of the German Engineering Federation (VDMA), Dresdner Verein zur Förderung der Fluidtechnik e. V. (DVF) and GWT-TUD GmbH. The organization and the conference location alternates every two years between the Chair of Fluid-Mechatronic Systems in Dresden and the Institute for Fluid Power Drives and Systems in Aachen. The symposium on the first day is dedicated to presentations focused on methodology and fundamental research. The two following conference days offer a wide variety of application and technology orientated papers about the latest state of the art in fluid power. It is this combination that makes the IFK a unique and excellent forum for the exchange of academic research and industrial application experience. A simultaneously ongoing exhibition offers the possibility to get product information and to have individual talks with manufacturers. The theme of the 12th IFK is “Fluid Power – Future Technology”, covering topics that enable the development of 5G-ready, cost-efficient and demand-driven structures, as well as individual decentralized drives. Another topic is the real-time data exchange that allows the application of numerous predictive maintenance strategies, which will significantly increase the availability of fluid power systems and their elements and ensure their improved lifetime performance. We create an atmosphere for casual exchange by offering a vast frame and cultural program. This includes a get-together, a conference banquet, laboratory festivities and some physical activities such as jogging in Dresden’s old town.:Group 1 | 2: Digital systems Group 3: Novel displacement machines Group 4: Industrial applications Group 5: Components Group 6: Predictive maintenance Group 7: Electro-hydraulic actuatorsDer Download des Gesamtbandes wird erst nach der Konferenz ab 15. Oktober 2020 möglich sein.:Group 1 | 2: Digital systems Group 3: Novel displacement machines Group 4: Industrial applications Group 5: Components Group 6: Predictive maintenance Group 7: Electro-hydraulic actuator

NFPA Fluid Powered Vehicle Challenge 2023

This report includes the design process undergone by Team Shifty in designing a vehicle for the NFPA’s Fluid Powered Vehicle challenge. The report covers the background of the competition, research done by the team, engineering specifications for the design, preliminary and final designs, the manufacturing plan and process, project management details, and several recommendations for future teams participating in the challenge. The National Fluid Power Association, NFPA, is a trade association with the goal of connecting fluid power companies and advancing fluid power. With the goal of advancement in mind, NFPA hosts an annual Fluid Powered Vehicle Challenge (FPVC). Since before the NFPA took over this challenge, Cal Poly has produced a team to compete. Team Shifty completed research into past Cal Poly teams as well as other competing university teams to define the engineering specifications for the new vehicle and decide the design directions. The final design includes a new frame to address issues with the last teams frame, a new hydraulic circuit design and selection of new components to improve the circuits performance in the FPVC events and reduce losses, and the addition of gear shifting to the vehicle. With respect to hydraulics, a new manifold was sourced to accommodate the simplified fluid circuit, along with a larger motor to allow the vehicle to operate at higher torque. The prior team’s pneumatic system was completely replaced by a pneumatic front gear shifting system. The electronics implemented was the same system as the previous year, including an STM microcontroller, Nextion touch screen display, and Hydraforce valve operator with only two solenoid valves. Working together, these components allowed the rider to toggle between three unique drive modes, including: direct, regen, and sprint. To produce a functional vehicle, research and planning was put into manufacturing and assembly processes as detailed in the manufacturing plan. The final product failed to perform as proposed in Team Shifty’s Scope of Work, as the vehicle’s rear chain consistently fell off during operation at the competition. This resulted in the vehicle not placing during a few of the challenges, including the Sprint and Endurance races. The cause of this failure was a function of the frame flexing under dynamic loading due to insufficient torsional stiffness, as well as the rear chain being too small to handle the large output torque of the upsized rear motor

Volume 1 – Symposium

We are pleased to present the conference proceedings for the 12th edition of the International Fluid Power Conference (IFK). The IFK is one of the world’s most significant scientific conferences on fluid power control technology and systems. It offers a common platform for the presentation and discussion of trends and innovations to manufacturers, users and scientists. The Chair of Fluid-Mechatronic Systems at the TU Dresden is organizing and hosting the IFK for the sixth time. Supporting hosts are the Fluid Power Association of the German Engineering Federation (VDMA), Dresdner Verein zur Förderung der Fluidtechnik e. V. (DVF) and GWT-TUD GmbH. The organization and the conference location alternates every two years between the Chair of Fluid-Mechatronic Systems in Dresden and the Institute for Fluid Power Drives and Systems in Aachen. The symposium on the first day is dedicated to presentations focused on methodology and fundamental research. The two following conference days offer a wide variety of application and technology orientated papers about the latest state of the art in fluid power. It is this combination that makes the IFK a unique and excellent forum for the exchange of academic research and industrial application experience. A simultaneously ongoing exhibition offers the possibility to get product information and to have individual talks with manufacturers. The theme of the 12th IFK is “Fluid Power – Future Technology”, covering topics that enable the development of 5G-ready, cost-efficient and demand-driven structures, as well as individual decentralized drives. Another topic is the real-time data exchange that allows the application of numerous predictive maintenance strategies, which will significantly increase the availability of fluid power systems and their elements and ensure their improved lifetime performance. We create an atmosphere for casual exchange by offering a vast frame and cultural program. This includes a get-together, a conference banquet, laboratory festivities and some physical activities such as jogging in Dresden’s old town.:Group A: Materials Group B: System design & integration Group C: Novel system solutions Group D: Additive manufacturing Group E: Components Group F: Intelligent control Group G: Fluids Group H | K: Pumps Group I | L: Mobile applications Group J: Fundamental