A review of high-speed electro-hydrostatic actuator pumps in aerospace applications: challenges and solutions

The continued development of electro-hydrostatic actuators (EHAs) in aerospace applications has put forward an increasing demand upon EHA pumps for their high power density. Besides raising the delivery pressure, increasing the rotational speed is another effective way to achieve high power density of the pump, especially when the delivery pressure is limited by the strength of materials. However, high-speed operating conditions can lead to several challenges to the pump design. This paper reviews the current challenges including the cavitation, flow and pressure ripples, tilting motion of rotating group and heat problem, associated with a high-speed rotation. In addition, potential solutions to the challenges are summarized, and their advantages and limitations are analyzed in detail. Finally, future research trends in EHA pumps are suggested. It is hoped that this review can provide a full understanding of the speed limitations for EHA pumps and offer possible solutions to overcome them

Energy Efficiency Improvement of Heavy-Load Mobile Hydraulic Manipulator with Electronically Tunable Operating Modes

The conventional hydraulic drive system for a heavy-load mobile manipulator is usually operated under single mode, such that both inlet/outlet and potential energy losses are large to lower the energy efficiency. In this paper, a novel electro-hydraulic drive system is presented to improve energy efficiency. Extended control degrees of freedom are obtained utilizing the independent metering valve and electronic controlled pump. Then, multiple operating modes are carried out pertaining to the cylinder, valve, and pump. To achieve both optimal energy efficiency and precise motion tracking, both multi-mode switching and multi-variable controller are designed to accommodate with time-varying and uncertain load characteristics. As a consequence, the inlet, outlet, and potential energy losses can be decreased simultaneously. The experimental validation is conducted by using a three-joint manipulator in a 2 t excavator. A duty cycle of movement including all three actuators and covering full load quadrants is used to evaluate the efficiency improvement. Compared with the conventional load sensing system, the proposed multi-mode switching system using the pump pressure with valve meter-in control mode yields a 25.8% energy-saving ratio. Furthermore, the pump flow with valve mete-out control mode yields a 35.3% energy-saving ratio. Using this combined control mode, higher efficiency can be obtained due to the minimum inlet losses, but faster dynamic response together with higher overshoot will appear. It is proved that the energy efficiency is improved, while the motion tracking performance is not degraded by introducing the multi-mode switching

Novel three-piston pump design for a slipper test rig

Slipper's micro motions including the squeezing motion, spinning motion, and tilting motion have a significant impact on its lubricating condition and dynamic behavior. However, few experimental studies are on these micro motions within a real axial piston pump, especially the slipper's spinning motion. The experimental investigations on the slipper in the past mainly focused on the parameters of the oil film such as pressure, thickness, and temperature. The sensors were often installed in the fixed swash plate when the cylinder block was chosen to rotate. Alternatively, the sensors were mounted in the fixed modified slipper when the swash plate rotated. The biggest challenge of the direct measurements of these micro motions is the space limitation for the sensor installation due to the compact structure of axial piston pumps as well as the slipper's macro motion. This paper presents a new three-piston pump for the slipper test rig which can provide enough installation space for the sensor. To realize the cylinder block balance, a hold-down plate is first introduced into this three-piston pump. In addition, a detailed set of relevant equations is derived to evaluate the functionality of the hold-down plate. Finally, the slipper's spinning motion was measured directly and continuously using this three-piston pump, which confirmed the capability of the slipper test rig

Research on wear prediction of piston/cylinder pair in axial piston pumps

The piston/cylinder pair is the critical lubricating interface of axial piston pumps. It suffers from excessive wear, especially under high output pressure. The performance degradation of the piston/cylinder pair is significant to be clarified. In this paper, a wear prediction method of the piston/cylinder pair is established by coupling the load-bearing and lubrication parameters calculation model and the wear calculation model. The models are validated through experiments. The experimental and simulated results show that the wear of two ends of the cylinder bore is severe in the specific ranges of circumferential angle. The time-varying wear process of the piston/cylinder pair can be obtained by using this method; therefore, the maintenance time can be predicted

Deadzone compensation control based on detection of micro flow rate in pilot stage of proportional directional valve

The pilot operated proportional directional valves (POPDVs) with a flow rate ranging from 100 to 1000 L/min are widely used in electro-hydraulic systems (EHSs). The deadzone of the pilot stage valve and its control compensation could significantly affect the position control performance for the main stage valve that could directly affect dynamics of EHSs In this paper, it is concluded that micro flow rates exist at the intermediate position of the valve based on the analysis of the continuity equation of the flow in the control chamber of the pilot stage. The micro flow rate is helpful to eliminate the discontinuity and unsmooth domain in the previous inverse deadzone compensation function. An improved deadzone detection method is proposed to calibrate the pilot valve flow characteristics which include the micro flow rate. This new method avoids the threshold selection of the main valve spool displacement which affects the detected deadzone values. Its detection processes are realized based on the pilot flow rate characterized by the speed of the main valve spool and the pilot valve displacement characterized by the solenoid current. The deadzone compensation control strategy based on the improved deadzone detection method is also designed. The experimental results using the steady-state position tracking and sinusoidal position tracking methods are verified. It is concluded that the tracking accuracy of the main valve spool position is effectively improved with this control strategy

Soft Actuators and Robotic Devices for Rehabilitation and Assistance

Soft actuators and robotic devices have been increasingly applied to the field of rehabilitation and assistance, where safe human and machine interaction is of particular importance. Compared with their widely used rigid counterparts, soft actuators and robotic devices can provide a range of significant advantages; these include safe interaction, a range of complex motions, ease of fabrication and resilience to a variety of environments. In recent decades, significant effort has been invested in the development of soft rehabilitation and assistive devices for improving a range of medical treatments and quality of life. This review provides an overview of the current state-of-the-art in soft actuators and robotic devices for rehabilitation and assistance, in particular systems that achieve actuation by pneumatic and hydraulic fluid-power, electrical motors, chemical reactions and soft active materials such as dielectric elastomers, shape memory alloys, magnetoactive elastomers, liquid crystal elastomers and piezoelectric materials. Current research on soft rehabilitation and assistive devices is in its infancy, and new device designs and control strategies for improved performance and safe human-machine interaction are identified as particularly untapped areas of research. Finally, insights into future research directions are outlined