modelling and energy comparison of system layouts for a hydraulic excavator

Abstract For decades the improvement of energy efficiency in mobile hydraulics has forced the research world to develop energy saving solutions and to redesign existing hydraulic circuits. This paper presents an overview about the state of the art of excavator valve systems based on open centre flow control (OFC) and a load sensing principle (LS). The purpose of this study is to compare different hydraulic systems on a middle size (9ton) excavator and to analyse the differences in term of energy saving and fuel consumption. Starting from a validate mathematical model of the considered hydraulic excavator whose functioning is in LS logic, many alternatives are proposed as flow on demand system, positive and negative flow control. Systems comparison has been done on typical excavator working cycles as trench digging and levelling referring to the JCMAS standard. An optimization tool, based on genetic algorithm, has been exploited for the definition of the optimal spool areas to reduce the pressure losses and by-pass flow rate maintaining identical controllability and performance

Modelling and Validation of Cavitating Orifice Flow in Hydraulic Systems

Cavitation can occur at the inlet of hydraulic pumps or in hydraulic valves; this phenomenon should be always avoided because it can generate abnormal wear and noise in fluid power components. Numerical modeling of the cavitation is widely used in research, and it allows the regions where it occurs more to be predicted. For this reason, two different approaches to the study of gas and vapor cavitation were presented in this paper. In particular, a model was developed using the computational fluid dynamics (CFD) method with particular attention to the dynamic modeling of both gaseous and vapor cavitation. A further lumped parameter model was made, where the fluid density varies as the pressure decreases due to the release of air and the formation of vapor. Furthermore, the lumped parameter model highlights the need to also know the speed of sound in the vena contracta, since it is essential for the correct calculation of the mass flow during vaporization. A test bench for the study of cavitation with an orifice was set up; cavitation was induced by increasing the speed of the fluid on the restricted section thanks to a pump located downstream of the orifice. The experimental data were compared with those predicted by CFD and lumped parameter models

A study on Correggio wall paintings: characterization of technique and materials of Abbey Church of S. Giovanni Evangelista in Parma, Italy

This study deals the materials of the sub- arch of the Del Bono chapel of the Abbey Church of S. Giovanni Evangelista in Parma, Italy, datable around 1523. The author of the painting is Antonio Allegri, known as Correggio (1489 – 1534), considered one of the greatest painters of the sixteenth century. Optical microscopy, micro-Raman spectroscopy, micro-Fourier Transform Infrared spectroscopy, scanning electron microscopy coupled with energy dispersive X-ray spectroscopy and gas chromatography coupled with mass spectrometry were selected in order to provide the higher set of significant data, limiting as much as possible sampling. The analysis has allowed to identify the pigments, characteristic of the epoch. The Correggio’s palette is composed by mineral pigments, sometimes expensive such as lapis lazuli, azurite and cinnabar, together with a wide range of earths or by synthetic pigments like smalt blue. From the amino acid content determination through GC/MS it was shown that, for all samples examined, the protein fraction is to be attributed to the presence of a mixture of egg and animal glue, present as binders in the samples containing lazurite, smalt, hematite, green earth and goethite. This allows to assume the use of a secco technique, also with pigments that do not need the employment of organic binding media on wall. For the gilding sample the hypothesis is that Au foil had been applied on a brown background where the Au foil is applied on the oil-based missione

Coupling excavator hydraulic system and internal combustion engine models for the real-time simulation

Rising energy costs and emissions restrictions force manufacturers to exploit new techniques to reduce fuel consumption and pollutant production. Many solutions have been proposed for off-road vehicles, mainly based on reduction of hydraulic losses, better control strategies and introduction of hybrid architectures. In these applications the optimization of the matching between hydraulic system and thermal engine is a major concern to improve system overall efficiency. The work presented in the paper is focused on the development of a method for the simulation of typical mobile machinery where hydraulic systems are powered by internal combustion engines; the proposed co-simulation approach can be useful in the development cycle of this machinery

Evaluation of Tooth Space Pressure and Incomplete Filling in External Gear Pumps by Means of Three-Dimensional CFD Simulations

The paper presents the computational fluid dynamics simulation of an external gear pump for fluid power applications. The aim of the study is to test the capability of the model to evaluate the pressure in a tooth space for the entire shaft revolution and the minimum inlet pressure for the complete filling. The model takes into account the internal fluid leakages and two different configurations of the thrust plates have been considered. The simulations in different operating conditions have been validated with proper high dynamics transducers measuring the internal pressure in a tooth space for the entire shaft revolution. Steady-state simulations have been also performed in order to detect the fall of the flow rate due to the incomplete filling of the tooth spaces when the inlet pressure is reduced. It has been demonstrated that, despite the need of a compromise for overcoming the limitation of considering fixed positions of the gears’ axes and of the thrust plates, significant results can be obtained, making the CFD approach very suitable for such analyses

Development and Application of Co-simulation and "Control- oriented" Modeling in the Improvement of Performance and Energy Saving of Mobile Machinery☆

Abstract Due to rising energy costs and tighter emissions restrictions from law regulations, mobile machinery and off-road vehicles manufacturers are forced to develop and exploit new techniques for the reduction of fuel consumption and pollutant emission. The main focus in this direction is the optimization of the matching between the fluid power circuit and the thermal engine to improve the efficiency of the hydraulic system and reducing the fuel consumption. A specific research activity has been started in this field by the authors to define methods and techniques for the mathematical simulation of off-road vehicles, where usually hydraulic systems are powered by internal combustion engines. The models proposed in the paper and the related results clearly show how these simulation tools can be used to improve the energy efficiency of the overall system, leading to an interesting reduction in fuel consumption by merely changing the engine rotational speed instead of adopting a constant-speed strategy

dynamic modelling of the swash plate of a hydraulic axial piston pump for condition monitoring applications

Abstract In the last years Prognostic and Health Management (PHM) has become one of the challenging topic in the engineering field. In particular, model-based approach for diagnostic relies on the development of a mathematical model of the system representing its flawless status. Once the model has been developed and carefully calibrated on experimental data referred to flawless pump condition the comparison between the model output and the real system output leads to the residual analysis, which gives a diagnosis of the component health. This paper presents the mathematical model of a hydraulic axial piston pump developed in order to replicate the dynamic behavior of the swash plate for PHM applications. The model has been developed on the basis of simplified hypotheses, a friction model between swash plate and bearings has been introduced. A detailed experimental activity was carried out to calibrate and validate the model with step tests and sweep tests. The comparison between numerical and experimental results shows a satisfying agreement and highlights the model capability to reproduce the swash plate dynamics. Future works will include tests with the pump in faulty conditions to evaluate the pump health state through the residual analysis of the swash plate position

AI-based condition monitoring of a variable displacement axial piston pump

Conventional condition monitoring involves integration of additional sensors for fault detection and diagnosis. They are costly and sensitive to faults themselves. To overcome these issues and data scarcity, simulation model data is used as a source of training data for Artificial Intelligence based condition monitoring of the axial piston pump. The sensitivity of the simulation model is improved by performing data augmentation. The classification of faults for condition monitoring in the model is performed by developing a classifier utilizing machine learning algorithm. This was tested for experimental, simulation, and augmented simulation data with respective accuracy scores of 84.8%, 70.1%, and 75.7%. Hence, augmented simulation data is a suitable option for online condition monitoring

Computational fluid dynamics (CFD) modelling and experimental validation of thermal processing of canned fruit salad in glass jar

In this paper the heat transfer of a fruit salad during the pasteurization treatment was investigated. The objective of the paper was to develop and validate a computational fluid dynamics (CFD) model for predicting the temperature profiles during the thermal processing of this sample. Samples of a commercial fruit salad, composed of five different fruits with different shapes, sizes and thermal properties, submerged in water/sugar syrup, were submitted to thermal treatments in a pilot plant and temperature profiles at different locations were experimentally recorded. Results showed that the slowest heating point (SHP) was positioned at 19–20% of the can height: fruit closest to the SHP such as pear presented the lowest F value. Moreover, F values resulted to be influenced by the distance from the jar bottom as function of natural convection motion of the syrup. CFD model simulations data were then successfully validated against the experimental ones: results, expressed as RMSE, showed a good fitting between calculated and experimental data, both for syrup (mean RMSE 1.47 C) and fruit pieces (mean RMSE 1.63 C). In addition, F values calculated from both experimental and simulated temperatures resulted very similar with only little differences. In conclusion, the proposed approach and mathematical model can thus be usefully applied for the simulation and prediction of thermal processes of canned fruit salad for process design and optimization