Single-stage electrohydraulic servosystem for actuating on airflow valve with frequencies to 500 hertz

An airflow valve and its electrohydraulic actuation servosystem are described. The servosystem uses a high-power, single-stage servovalve to obtain a dynamic response beyond that of systems designed with conventional two-stage servovalves. The electrohydraulic servosystem is analyzed and the limitations imposed on system performance by such nonlinearities as signal saturations and power limitations are discussed. Descriptions of the mechanical design concepts and developmental considerations are included. Dynamic data, in the form of sweep-frequency test results, are presented and comparison with analytical results obtained with an analog computer model is made

Modelling and Validation of a Regenerative Shock Absorber System

Abstract— For effective energy regeneration and vibration dampening, energy regenerative suspension systems have received more studies recently. This paper presents the dynamic modeling and a test system of a regenerative shock absorber system which converts vibration motion into rotary motion through the adjustment of hydraulic flow. Hydraulic circuit configuration achieves the one way flow and energy regeneration during both compression and extension strokes. The dynamic modeling is performed for the evaluation of design concept and the feasibility studies of regenerative shock absorber system theoretically. Based on simulated results, the efficiency of hydraulic transmission is optimized and validated in test system. The results show that the performance of hydraulic fluid, the features of rotary motion and the capability of energy regeneration are verified and compared between dynamic modeling and experiments. Meanwhile, the average power of 118.2W and 201.7W with the total energy conversion of 26.86% and 18.49% can be obtained based on experiments under sinusoidal inputs with 0.07854m/s and 0.1256m/s respectively

Design and analysis of a high performance valve

Most valves available in the fluid power industry today are capable of achieving either a large flow rate or a quick response time; however, often they are unable to deliver both simultaneously. Commercially available valves that can produce both at the same time require complex geometries with multiple actuation stages and piloting pressures, making them expensive components. To establish their active usage in applications across the fluid power industry, a reduction in price for these components is paramount. The Energy Coupling Actuated Valve (ECAV) is capable of solving the large flow rates with fast actuation speeds trade-off by utilizing a new, high performance actuation system. The Energy Coupling Actuator (ECA) is an innovative actuation system that separates the kinetic energy source mass from the actuation mass. Intermittently coupling the actuator to a constantly rotating disk creates an energy transfer from the rotating disk’s kinetic energy to the normally stationary actuator. This intermittent coupling process is controlled by changing the magnetic field inside the actuator’s two coils. Magnetorheological (MR) fluid resides in a 0.5mm fluid gap between the spinning disk and the actuator, and when the magnetic flux builds across this gap, it causes the actuator to move rapidly in a translational movement. The MR fluid changes to a solid between the gap and frictionally binds the actuator to the disk, causing the actuator to move up or down, depending on which coil is actuated on the spinning disk. The liquid-solid conversion from the MR fluid occurs in less than one millisecond and is completely reversible. The shear strength of the fluid is proportional to the magnetic field strength inside the system. The actuator is connected to either a poppet or spool assembly for valve actuation, and the position is controlled through intermittently binding the actuator to the disk. Two valve prototypes, one poppet and one spool type, were machined, and concept validation has been done in both simulation and experimentally. Experimental results show that the poppet reaches a 4mm displacement in 19.8ms opening and 17ms in closing under 33 L/min flow. The spool valve experimentally transitioned in 4.8ms at the same flow rate

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

Improving Energy Efficiency and Motion Control in Load-Carrying Applications using Self-Contained Cylinders

Because of an increasing focus on environmental impact, including CO2 emissions and fluid spill pollution, inefficient hydraulic systems are being replaced by more environmentally friendly alternatives in several industries. For instance, in some offshore applications that have multiple diesel generators continuously running to produce electricity, all hydraulic rotating actuators supplied from a central hydraulic power unit have been replaced with AC induction motors containing a variable frequency drive and gearbox. However, hydraulic linear actuators are still needed in most load-carrying applications mainly because of their high reliability associated with external impact shocks. Moreover, their force capacity is higher than that of their linear electromechanical counterparts. Valve-controlled linear actuators (cylinders) supplied from a centralized hydraulic power unit are standard in offshore load-carrying applications. In addition to the advantages mentioned above of hydraulic linear actuators, they have, nevertheless, a number of important drawbacks, which include: 1) a high level of energy consumption due to significant power losses caused by flow throttling in both the pipelines and valves, 2) reduced motion performance due to the influence of load-holding valves, 3) high CO2 emissions and fuel costs related to the diesel generator that supplies electricity to the hydraulic power unit, 4) significant potential for hydraulic fluid leakage because of many leakage points, 5) demanding efforts with respect to installation and maintenance, as well as 6) costly piping due to the centralized hydraulic power supply. The work presented in this dissertation and the appended papers are devoted to replacing inefficient hydraulic linear actuation systems traditionally used in offshore load-carrying applications with more environmentally friendly solutions. Two alternative technologies are identified, namely electro-mechanical and electro-hydraulic self-contained cylinders. The feasibility of replacing conventional valve-controlled cylinders with self-contained cylinder concepts is investigated in two relevant case studies.publishedVersio

Experimental study of 3D movement in cushioning of hydraulic cylinder

A double acting cylinder operation has been fully monitored in its key functional parameters, focused on characterization of end-of-stroke cushioning and starting phases. Being the cylinder performance reliant in the piston constructive geometry, the number and location of piston circumferential grooves is a significant parameter affecting the internal cushioning system performance. An eddy current displacement sensor assembled in the piston allows assessment of piston radial displacement inside the cylinder tube, which is directly related with the studied operating phases. Due to such 3D displacements, the piston becomes as an active and self-adjusting element along the functional cycle of the cylinder. Mechanical joints orientation and operating pressure are also relevant parameters affecting piston radial displacement and, thus, the cushioning and starting performance. Computational Fluid Dynamics (CFD) results confirm the observed functional role of the perimeter grooves; the flow and pressure distributions, where develops a significant radial force, are also in accordance with the registered radial displacement.Peer ReviewedPostprint (published version

Advanced Control Strategies for Mobile Hydraulic Applications

Mobile hydraulic machines are affected by numerous undesired dynamics, mainly discontinuous motion and vibrations. Over the years, many methods have been developed to limit the extent of those undesired dynamics and improve controllability and safety of operation of the machine. However, in most of the cases, today\u27s methods do not significantly differ from those developed in a time when electronic controllers were slower and less reliable than they are today. This dissertation addresses this aspect and presents a unique control method designed to be applicable to all mobile hydraulic machines controlled by proportional directional valves. In particular, the proposed control method is targeted to hydraulic machines such as those used in the field including construction (wheel loaders, excavators, and backhoes, etc.), load handling (cranes, reach-stackers, and aerial lift, etc.), agriculture (harvesters, etc.), forestry, and aerospace. For these applications the proposed control method is designed to achieve the following goals: A. Improvement of the machine dynamics by reducing mechanical vibrations of mechanical arms, load, as well as operator seat; B. Reduction of the energy dissipation introduced by current vibration damping methods; C. Reduction of system slowdowns introduced by current vibration damping methods. Goal A is generally intended for all machines; goal B refers to those applications in which the damping is introduced by means of energy losses on the main hydraulic transmission line; goal C is related to those applications in which the vibration attenuation is introduced by slowing down the main transmission line dynamics. Two case studies are discussed in this work: 1. Hydraulic crane: the focus is on the vibrations of the mechanical arms and load (goals A and B). 2. Wheel loader: the focus is on the vibrations of the driver\u27s seat and bucket (goals A and C). The controller structure is basically unvaried for different machines. However, what differs in each application are the controller parameters, whose adaptation and tuning method represent the main innovations of this work. The proposed controller structure is organized so that the control parameters are adapted with respect to the instantaneous operating point which is identified by means of feedback sensors. The Gain Scheduling technique is used to implement the controller whose set of parameters are function of the specific identified operating point. The optimal set of control parameters for each operating point is determined through the non-model-based controller tuning. The technique determines the optimal set of controller parameters through the optimization of the experimental machine dynamics. The optimization is based on an innovative application of the Extremum Seeking algorithm. The optimal controller parameters are then indexed into the Gain Scheduler. The proposed method does not require the modification of the standard valve controlled machine layout since it only needs for the addition of feedback sensors. The feedback signals are used by the control unit to modify the electric currents to the proportional directional valves and cancel the undesired dynamics of the machine by controlling the actuator motion. In order for the proposed method to be effective, the proportional valve bandwidth must be significantly higher than the frequency of the undesired dynamics. This condition, which is typically true for heavy machineries, is further investigated in the research. The research mostly focuses on the use of pressure feedback. In fact, although the use of position, velocity, or acceleration sensors on the vibrating bodies of the machine would provide a more straightforward measurement of the vibration, they are extremely rare on mobile hydraulic machines where mechanical and environmental stress harm their integrity. A comparison between pressure feedback and acceleration feedback alternatives of the proposed method is investigated with the aim to outline the conditions making one alternative preferable over the other one (for those applications were both alternatives are technically viable in terms of sensors and wiring reliability). A mid-sized hydraulic crane (case study 1) was instrumented at Maha Fluid Power Research Center to study the effectiveness of the proposed control method, its stability and its experimental validation. Up to 30% vibration damping and 40% energy savings were observed for a specific cycle over the standard vibration damping method for this application. The proposed control method was also applied to a wheel loader (case study 2), and up to 70% vibrations attenuation on the bucket and 30% on the driver\u27s cab were found in simulations. These results also served to demonstrate the applicability of the control method to different hydraulic machines. Improved system response and a straightforward controller parameters tuning methodology are the features which give to the proposed method the potential to become a widespread technology for fluid power machines. The proposed method also has potential for improving several current vibration damping methods in terms of energy efficiency as well as simplification of both the hydraulic system layout and tuning process

Advanced hydraulic systems for next generation of skid steer loaders

Fluid power systems have been extensively used in off highway applications like skid steer loaders, wheel loaders, excavators since many years. Work has been done by both industry and academia to improve efficiency, reduce noise and leakages in these systems. With increasing competition in the market, importance is now also given to operator comfort and machine productivity in off highway applications. Mobile, off – highway vehicles like Skid-steer loaders are widely used in labour saving applications like loading earth into a truck, dig and move material on construction sites to, clean roads, clear snow from roads etc. To carry out these jobs in limited spaces, skid steer loaders need tight turning radius. For this reason, these machines have a short wheelbase which prevents the use of suspensions in these vehicles. The absence of a suspension system exposes the vehicle to ground vibrations of high magnitude and low frequency. Vibrations reduce operator comfort, productivity and life of components. This thesis will discuss control strategies for vibration damping of skid steer loader using the hydraulic boom cylinder as the active suspension element, which is equivalent to a spring–damper. Along with vibrations, the machine productivity is also hampered by material spillage which is caused by the tilting of the bucket due to the extension of the boom. This dissertation will discuss the development of a robust path-planning control algorithm which adapts to the position of the boom to maintain a level load to achieve bucket self-leveling. Another reason for reduced productivity in skid steer loaders is slow in site travel speeds. This dissertation also concentrates on reducing the in-job cycle time by developing a control strategy to smooth speed shift the drive motors keeping the pump flow constant. To synthesize these proposed control algorithms, high fidelity hydraulic and mechanical models of the skid steer loader are created. Ultimately, the control algorithms derived in this dissertation help in improving operator comfort and machine productivity

Hydrogen-methane fuel control systems for turbojet engines

Design, development, and test of a fuel conditioning and control system utilizing liquid methane (natural gas) and liquid hydrogen fuels for operation of a J85 jet engine were performed. The experimental program evaluated the stability and response of an engine fuel control employing liquid pumping of cryogenic fuels, gasification of the fuels at supercritical pressure, and gaseous metering and control. Acceptably stable and responsive control of the engine was demonstrated throughout the sea level power range for liquid gas fuel and up to 88 percent engine speed using liquid hydrogen fuel