Towards Automation and Improved Fuel Economy with System Architecture Design of a Non-Road Working Machine

Increasing levels of automation and interest in fuel economy have been affecting the system design of non-road working machines. Both fuel economy and automation have been active research areas in non-road working machines. It is unlikely that in the near future electrification will solve the energy challenges of machines operating for long periods in forests, mines or fields. Therefore, it is necessary to increase the fuel efficiency of such machines with conventional technology, taking into account the fact that automation, along with the diversity of subcontractors and performance requirements, has increased the complexity of these machines. A modular abstraction layer architecture is proposed for the machine level to support the development of automation and comparison of fuel economy. The architecture is developed and selected on the premise that a machine is operated with different automation levels between manual and autonomous operation and employs alternative control methods for different operation conditions. The designed system architecture is compared with alternative approaches by using trade-off analysis with defined scoring functions. For improving fuel economy and demonstrating the capability of the designed architecture, a modular power management architecture is realised to meet the performance requirements of the machine. This architecture breaks the system down into smaller modules to facilitate design and development. Further, the architecture separates control of the power sources from the consumers, providing a new degree of freedom in designing the subsystems, as the consumer modules are not coupled with the engine. The improvement in fuel economy is based on the MinRpm control strategy, which is integrated with the power management architecture. The objective of MinRpm is to minimise the rotational speed of the engine, which leads to the engine operating with higher partial loads and in a higher fuel efficiency region. In addition, the components and subsystems that use relative constant torque use less energy when the rotational speed is lower. Devices of this kind are typically fans, fixed displacement pumps and oil coolers, in which the torque demand is not highly dependent on the rotational speed of the engine. The proposed modular power management architecture with the MinRpm control strategy does not require any new components to make improvements in fuel economy, which, in turn, reduces the implementation costs. In both simulations and in experimental tests with a municipal wheel loader, the control method resulted in fuel savings of 11 to 22% compared with a series-production machine on the market. The comparison is realised by integrating the emulated series-production machine control with the same system architecture that was developed for the power management system with MinRpm approach. Therefore, both control methods are realised with the same wheel loader, which eliminates discrepancy of the component properties. Realisation of the alternative control methods in the designed system architecture demonstrates the compatibility needed when the machine is operated with different operating modes from manual to autonomous. Before fully autonomous machines become real, a different level of automation is needed to perform efficiently and safely in all operation conditions. Therefore, the designed system architecture is capable of rerouting control signals and control flows, while safety features are guaranteed when the control mode is changed

Volume 2 – Conference: Wednesday, March 9

10. Internationales Fluidtechnisches Kolloquium:Group 1 | 2: Novel System Structures Group 3 | 5: Pumps Group 4: Thermal Behaviour Group 6: Industrial Hydraulic

Electrified Powertrains for a Sustainable Mobility: Topologies, Design and Integrated Energy Management Strategies

This Special Issue was intended to contribute to the sustainable mobility agenda through enhanced scientific and multi-disciplinary knowledge to investigate concerns and real possibilities in the achievement of a greener mobility and to support the debate between industry and academic researchers, providing an interesting overview on new needs and investigation topics required for future developments

Towards Energy-Efficient Electrified Mobile Hydraulics : Considering Varying Application Conditions

In the face of global warming, companies in all kinds of industries need to take measures to reduce the use of fossil fuels, which is explicitly enforced by more and more upcoming emission legislation in many countries. In the case of heavy-duty mobile machines (HDMMs), a currently high-emitting sector, the most feasible method of reducing harmful emissions during operation is battery-based electrification. However, the relatively low capacities and high costs of available battery packs are restricting the operation times as well as upper power limits of battery-electric HD-MMs—at least under economically feasible conditions. In this scenario, the typically low energy-efficiencies of conventional hydraulic systems, which are essential for realizing linear actuation on HDMMs, are becoming more critical than ever before, and more efficient alternative concepts are required. As an answer to this demand, this thesis and the six publications on which it is based analyze how alternative hydraulic concepts for electrified HDMMs should look like, and two specific concepts are proposed as well as evaluated. In this scope, the focus is not only on improving the efficiency but also on other aspects that can prevent or accelerate the success of alternative hydraulic concepts on the market, such as costs and feasibility. Since those aspects cannot be analyzed in isolation from the application conditions, the essential characteristics of HDMMs and the differences of those characteristics between HDMM types are elaborated systematically. Furthermore, the implications of the transition from internal combustion engines (ICEs) to electric machines (EMs) as the prime movers for hydraulic pumps are identified by means of a literature review. Considering the insights from the analyses of those aspects, already existing hydraulic concepts—i.e., conventional as well as proposed alternatives for improved efficiency—are reevaluated, and beneficial elements of those concepts are filtered out for constructing two new concepts. Those two proposed concepts are characterized by a modular approach in which actuators can be valve-controlled, which might be less efficient but more cost-effective, or pump-controlled, as an alternative for more efficient yet costly actuation of selected functions on the HDMM. Simulation studies are used to demonstrate the efficiency of both concepts under varying configurations that are enabled through the modular nature of the concepts, and the differences in applying them on a telehandler, wheel loader, or excavator are analyzed. For the second concept, which is based on displacement-control and performed best in the simulations, a cost analysis is used to prove additionally that reasonably short payback times of the increased investment costs can be reached in different scenarios. Furthermore, the efficiency performance as well as feasibility—in terms of using commercially available components only and achieving good controllability—are experimentally validated on a telehandler

Energy Efficient Control of Hydrostatic Drive Transmissions: A Nonlinear Model-Based Approach

The high standard of living in industrial countries is based on the utilization of machines. In particular, the tasks performed with hydraulic work machines (HWMs) are essential in numerous industrial fields. Agriculture, mining, and construction are just a few examples of the lines of business that would be inconceivable today without HWMs. However, rising oil prices and competing technologies are challenging the manufacturers of these machines to improve their fuel economy.Despite the fact that energy efficiency research of hydraulic systems has been active for more than a decade, there seems to be a significant gap between industry and academia. The manufacturers of HWMs have not adopted, for example, novel system layouts, prototype components, or algorithms that require powerful control units in their products.The fuel economy of HWMs can be increased by utilizing system information in control algorithms. This cost-effective improvement enables operation in challenging regions and closer to the operating boundaries of the system. Consequently, the information about the system has to be accurate. For example, reducing the rotational speed of the engine has proven effective in improving the energy efficiency, but it increases the risk of even stalling the engine, for instance in situations where the power generation cannot meet the high transient demand. If this is considered in the controller with low uncertainty, fuel economy can be improved without decreasing the functionality of the machine.This thesis studies the advantages of model-based control in the improvement of the fuel economy of HWMs. The focus is on hydrostatic drive transmissions, which is the main consumer of energy in certain applications, such as wheel loaders.We started by developing an instantaneous optimization algorithm based on a quasi-static system model. The control commands of this fuel optimal controller (FOC) were determined based on cost function, which includes terms for fuel economy, steady-state velocity error, and changes in the control commands.Although the use of quasi-static models is adequate for steady-state situations, the velocity tracking during transients and under load changes has proven to be inadequate. To address this issue, a high-performance velocity-tracking controller was devised. Full state feedback was assumed, and we resorted to a so-called D-implementation, which eliminates, for example, the need for the equilibrium values of pressure signals. The nonlinearities of the system were considered with the state-dependent parameters of the linear model.In the next step, a nonlinear model predictive controller combined fuel economy control and velocity tracking. To the best of the author’s knowledge, this is the first time that the model predictive control scheme has been utilized with such a detailed system model that also considers the hydraulic efficiencies and torque generation of the engine. This enables utilizing the controller as a benchmark of control algorithms for non-hybrid hydrostatic drive transmissions that do not require information about the future.The initial tests of all the controllers were conducted with a validated simulation model of a research platform machine, a five-ton municipal tractor. In addition, the FOC and velocity-tracking controller were implemented into the control system of the machine. The practical worth of the FOC was proven with a relatively unique field experiment set-up that included, for example, an online measurement system of fuel consumption and autonomous path following. The fuel economy improved up to 16.6% when compared with an industrial baseline controller. The devised velocity-tracking concept was also proven as a significant reduction of error was observed in comparison with classic literature solutions, namely state feedback and proportional-integral-derivative controllers

New Approaches in Automation and Robotics

The book New Approaches in Automation and Robotics offers in 22 chapters a collection of recent developments in automation, robotics as well as control theory. It is dedicated to researchers in science and industry, students, and practicing engineers, who wish to update and enhance their knowledge on modern methods and innovative applications. The authors and editor of this book wish to motivate people, especially under-graduate students, to get involved with the interesting field of robotics and mechatronics. We hope that the ideas and concepts presented in this book are useful for your own work and could contribute to problem solving in similar applications as well. It is clear, however, that the wide area of automation and robotics can only be highlighted at several spots but not completely covered by a single book

Spatial and Temporal Considerations in Vehicle Path Tracking With an Emphasis on Spatial Robustness

This dissertation researches the task and path management of an autonomous vehicle with Ackerman-type steering. The task management problem was approached as a path training operation in which a human operator drives the desired path through an environment. A training trajectory is converted into a series of path segments that are driveable by the autonomous vehicle by first fitting a general path to the dataset. Next, transition segments are added to the general path to match the vehicle velocity and steering angle rate limit. The path management problem has been approached by first deriving a kine- matic model of the vehicle. The time domain model is expressed in the frequency domain and then converted into a spatial frequency domain. Next, a stability crite- rion is derived and used in the synthesis of a spatially-robust path controller

Time Localization of Abrupt Changes in Cutting Process using Hilbert Huang Transform

Cutting process is extremely dynamical process influenced by different phenomena such as chip formation, dynamical responses and condition of machining system elements. Different phenomena in cutting zone have signatures in different frequency bands in signal acquired during process monitoring. The time localization of signal’s frequency content is very important. An emerging technique for simultaneous analysis of the signal in time and frequency domain that can be used for time localization of frequency is Hilbert Huang Transform (HHT). It is based on empirical mode decomposition (EMD) of the signal into intrinsic mode functions (IMFs) as simple oscillatory modes. IMFs obtained using EMD can be processed using Hilbert Transform and instantaneous frequency of the signal can be computed. This paper gives a methodology for time localization of cutting process stop during intermittent turning. Cutting process stop leads to abrupt changes in acquired signal correlated to certain frequency band. The frequency band related to abrupt changes is localized in time using HHT. The potentials and limitations of HHT application in machining process monitoring are shown