PhD-Theses completed in 2007
Control Strategy for Energy Efficient Fluid Power Actuators
Utilizing Individual Metering
Institute of Technology
Linköpings University, Linköpings, Sweden
This
thesis presents a solution enabling lower losses in hydraulic actuator
systems. A mobile fluid power system often contains several different
actuators supplied with a single load sensing pump. One of the main
advantages is the need of only one system pump. This makes the fluid
power system compact and cost-effective.
A hydraulic load often consists of two ports, e.g. motors and
cylinders. Such loads have traditionally been controlled by a valve
that controls these ports by one single control signal, namely the
position of the spool in a control valve. In this kind of valve, the
inlet (meter-in) and outlet (meter-out) orifices are mechanically
connected. The mechanical connection makes the system robust and easy
to control, at the same time as the system lacks flexibility. Some of
the main drawbacks are:
1) The fixed relation between the inlet and outlet orifices
in most applications produce too much throttling at the outlet orifice
under most operating conditions. This makes the system inefficient.
2) The flow directions are fixed for a given spool position;
therefore, no energy recuperation and/or regeneration ability is
available.
In this thesis a novel system idea enabling, for example, recuperation
and regeneration is presented. Recuperation is when flow is taken from
a tank, pressurized by external loads, and then fed back into the pump
line. Regeneration is when either cylinder cham-bers (or motor ports)
are connected to the pump line. Only one system pump is needed.
Pressure compensated (load independent), bidirectional, poppet valves
are proposed and utilized.
The novel system presented in this thesis needs only a position sensor
on each compensator spool. This simple sensor is also suit-able for
identification of mode switches, e.g. between normal, differential and
regenerative modes. Patent pending.
The balance of where to put the functionality (hardware and/or
software) makes it possible to manoeuvre the system with main-tained
speed control in the case of sensor failure. The main reason is that
the novel system does not need pressure transducers for flow
determination. Some features of the novel system:
1) Mode switches The mode switches are accomplished without
knowledge about the pressures in the system
2) Throttle losses With the new system approach, choice of
control and measure signals, the throttle losses at the control valves
are reduced
3) Smooth mode switches The system will switch to
regenerative mode automatically in a smooth manner when possible
4) Use energy stored in the loads The load, e.g. a cylinder,
is able to be used as a pump when possible, enabling the system to
re-cuperate overrun loads
The system and its components are described together with the control
algorithms that enable energy efficient operation.
Meas-urements from a real application are also presented in the thesis.
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Bořek Dvořák
Dynamical Analysis of Testing Board with Six Degrees of Freedom
Department of Mechanical Engineering
Technical University of Liberec, Liberec, Czech Republic
The main content of the thesis is the creation of mathematical model
and simulation of dynamical properties of structure, which is called
testing board with six degree of freedom. Testing board is a real
testing device, which was developed and built on the TU Liberec.
Theoretical part of the thesis is focused on problems with the
mathematical modelling of larger structures with using of algorithms,
which are generally called the reduction methods. Especially the
algorithm called Craig-Bampton is described. The thesis contains two
main sections. The first section is focused on the creation of model
with finite element method utilization, using the software ANSYS. ANSYS
was used for eigenfrequencies and eigenvectors computations. The second
part is based on solutions of forced vibration analysis. Comparison
between model only with rigid parts and the model with flexible parts
is presented. This com-parison is used to clarify the effect of
flexible parts on the movement of the inspected body by the excitation
with deterministic and pseudo-stochastic signals. The Craig- Bampton
algorithm is used for the transfer of flexible parts from ANSYS to
ADAMS, which was used for vibration analysis. The experimental
operation deflection shapes analysis (ODS) is also a part of this
thesis. The com-parison between experimental and computed results is
presented.
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Contributions to Magneto-Rheological Fluid Applications in
Squeeze Mode
Institute of Machine Design and Hydraulic Drives
Johannes Kepler University of Linz, Linz, Austria
Magneto-rheological (MR) fluids are suspensions of micron-sized
ferromagnetic particles in a non-magnetic carrier fluid. The es-sential
characteristic behaviour is the rapid and reversible transition from
the state of a Newtonian-like fluid to the behaviour of a stiff
semi-solid by applying a magnetic field of about 0.1-0.4 Tesla. This
feature, called the magneto-rheological (MR)-effect, can be understood
from the fact that the particles form chain-like structures aligned in
field direction. The MR-fluid offers three modes of operation. Either
the direct shear motion of two magnetic poles separated by the fluid
generates shear forces, or the valve mode re-stricts the flow through
passages. Due to its highly non-linear behaviour, the third mode of
operation, the squeeze mode, is up to now used for small amplitude
vibration damping only.
A test rig for the exploration of the MR-fluid behaviour was designed
for experimental purposes. Special emphasis was put on the dependence
of the MR-fluid response with respect to parameter variations of the
applied static magnetic field, the cyclic loading amplitude and
frequency values. Further, the cavitation phenomenon was investigated.
Several attempts to describe the squeeze mode phenomenon with Finite
Element simulations using different material laws such as a
rigid-viscoplastic material law, an overstress power law and extended
Drucker Prager models are presented.
Thereby attained new perceptions gave reason to design an adaptive
magneto-rheological fluid bearing in squeeze mode behaviour for
industrial applications. A modification of the existing test rig was
accomplished to prove the expected behaviour and benefits of this new
concept. The substantial innovation is the rapid control of the radial
load carrying capacity using the electric current as con-trol variable.
Furthermore, high load carrying capacities at low rotational speed can
be accomplished whereby rate dependence is negligible. Particularly for
the bearing in squeeze-mode, the interrelationship of the radial force
and the magnetic flux induction as well as the squeeze gap geometry is
of great relevance. For design engineering, preferably simple
analytical approaches describing the load carrying capacity of such a
bearing are of interest and are discussed in this thesis including a
virtual power law with a von Mises yield law and a Levi-Mises flow rule.
A promising industrial application of the magneto-rheological fluid
bearing in squeeze mode can be found in the field of rolling
technologies. The potential of usage is as a fully dynamic actuator
capable of correcting, for instance, flatness defects of the strip. The
application is studied by an example and by some design principles.
Restrictions and problems of the application of MR-fluids are
discussed, statements and ideas for further work necessary for a final
industrial application are presented. Furthermore, a patent of the
magneto-rheological fluid bearing in squeeze mode was suc-cessfully
applied and published and is presented in this work.
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Axial Piston Pump leakage modelling and measurement
Institute of Machines and Structures
Cardiff School of Engineering, Cardiff, UK
This thesis is concerned with the dominant leakage characteristics of
an axial piston pump. Results have been obtained from a combination of
analysis, Computational Fluid Dynamics (CFD) and experimental work, and
have added to existing knowledge in this field. The measurement of
slipper leakage within an axial piston pump is impossible due to
additional leakage from the pistons and between the cylinder barrel and
port plate. It may only be determined by analysis and this aspect has
been studied via a new CFD simulation.
Further progress has been made experimentally on slipper leakage, a new
test apparatus was designed and developed by the au-thor and
comparisons have been made with parallel analytical work. Previous
research in this area has concentrated on single-landed slippers and
leakage rates from such slippers have been examined, however only under
static conditions. The work in this thesis is the first to consolidate
experimental studies on multiple-land slippers, and the first to
measure slipper leakage under dynamic conditions. These results have
been compared with both CFD simulations and a new theoretical study
undertaken in parallel with this work. The new test apparatus allowed
measurement of both leakage and groove pressure under a range of
operating conditions. It was established that the presence of a groove
reduces the restoring moment produced, and hence enables the slipper to
operate with an appropriate angle of tilt, thus permitting hydrodynamic
lift to more readily exist. However, this occurs at a cost of increased
leak-age.
In addition to the experimental work on slippers, the time-varying
pressures within selected cylinders of an axial piston pump were
measured. In parallel, a fully dynamic CFD model of a pump was
produced. This model included all leakage paths from the pump. It was
discovered that the port leakage dominated the overall leakage from the
pump, with piston leakage being insignificant. This model was also used
to predict the flow and pressure ripple from the pump and the
predictions were compared with measure-ments.
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Energy efficient
electric-hydrostatic drive concept using the example of an injection
moulding machine
Institute fur Fluidtechnik
Technical University of Dresden, Dresden, Germany
This study deals with the development and experimental testing of an
electric-hydrostatic drive concept using the example of an injection
moulding machine. Furthermore, it identifies and compares the energy
requirements of various different injection moulding machines which are
available in today's market.
The study examines the static and dynamic performance of speed variable
pumps in stationary applications. Furthermore, it pro-vides information
on the design and calculation of electric-hydrostatic drive concepts.
Testing of the newly developed system's en-ergy consumption in
comparison with other commercially available drive units for injection
moulding machines provides objective guidance for the selection of a
suitable drive concept from an energy consumption perspective. At the
same time, an analysis of the results concerning the drive technology
highlights the advantages and disadvantages of the various concepts and
provides direction for future development.
Based on two fixed displacement pumps, the electric-hydrostatic circuit
designed for an injection moulding machine exercises flow control by
adjusting the pump speed. Hydraulic fluid is fed to the active
hydraulic cylinder through directly controlled 2/2 way switching
valves. The application of two drive units allows on the one hand pump
controlled differential cylinder operation and on the other hand the
coupling of these units in the event of a major increase in output
requirements during the injection phase while the dynamic efficiency of
synchronous servo motors remains high. Any ancillary movements
including ejectors or core pullers can be supplied by a hydraulic
accumulator and controlled by proportional valves. This set-up enables
simultaneous operation of the ancil-lary movements while the mould
stroke cylinder, injection cylinder or plasticizing motor are working.
In conclusion, guidelines are established which provide information on
the design of electric-hydrostatic drive concepts in stationary
applications.
The prototype of an injection moulding machine which was subject to
examination displays increased energy efficiency and less operating
noise compared with conventional hydraulic drive systems. This can be
attributed to a reduced speed under partial load and the standstill of
units during break intervals as well as the application of low-noise
pumps.
In this study, five injection moulding machines with the latest
generation of different drive concepts are examined from the
per-spective of energy consumption. The analyses cover both well proven
drive units and innovative hydraulic and electro-mechanical designs.
They reveal that the energy efficiency of injection moulding machines
can only be enhanced by a systematic development of drive concepts. In
addition to improved energy utilisation during plasticizing, which
accounts for the largest part of energy consump-tion, the selection of
a suitable drive concept can also lead to major savings during hold on
pressure, mould opening/closing, ejection, carriage movement and break
phases.
The examination results of the test machine with an
electric-hydrostatic drive unit show that by using speed variable
pumps, a major reduction in energy requirement can be achieved in
virtually all phases of the cycle when compared with conventional
hy-draulic concepts.
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Development of a magneto-rheological active damping system
to improve the yaw response of a racing vehicle
Institute of Machines and Structures
Cardiff School of Engineering, Cardiff, UK
This thesis presents the development of the first
ever racing vehicle yaw control system that utilizes active dampers to
provide a corrective yaw moment through the manipulation of tire
contact patch loads during transient vehicle handling maneuvers. The
study has focused on the following three key areas:
1) The design of a magneto-rheological
(MR) damper
The damping requirements of a racing
vehicle are investigated. A prototype magneto¬rheological
damper is proposed and evalu-ated using magnetic finite element
techniques. The manufactured prototype is subsequently tested and
benchmarked against a passive racing damper and a commercially
available MR damper. Consideration is given to the current driver
circuit required, the damper response time to increasing and decreasing
demand signals and sealing and bearing requirements.
2) A novel yaw damping strategy utilizing
active MR dampers.
This work proposes a novel active damping
strategy for vehicle yaw control. The dampers are used to control both
the pitch and roll damping distribution during transient vehicle
handling maneuvers. It is shown that this approach improves the
functionality of previous damper based yaw control that only considered
roll damping distribution.
3) In-Vehicle implementation and track
testing
An in-vehicle damper control system is
developed using hardware that has not previously been employed in this
application. This study is the first to apply a damper based yaw
control system to a racing vehicle. Track testing of the racing vehicle
fitted with the damper control system is used to demonstrate the
potential improvements achievable in the context of lap time,
subjective driver feel and measured yaw error.
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Life in the Water Hydraulic System
Institute of Hydraulics and Automation
Tampere University of Technology
Because of physical and
biological contamination, filtration may turn out to be problematic in
water hydraulic systems. Contami-nation may quickly increase the
pressure difference over the filter cartridge; consequently, this
research aimed to test the depth type filter cartridge and to determine
the effects of microbial growth and particulate contamination on
filtration in a water hydraulic sys-tem. Experiments were run by using
tap water with R2A as a biological contaminant and ISOMTD as a particle
contaminant.
The contamination control of water hydraulic systems starts with the
design of the system. Special features of water hydraulics must be
taken into account while designing, because the best way to prevent
problems caused by biological contamination is to build a system with
minimum interface between pressure media and the surrounding
environment. In addition, clean work practices during start-up and
maintenance have long-term effects on the operation of the system.
Particle
contamination can be filtered without special applications, when the
biological contamination level is low; but when mi-crobial growth has
been induced, the best way of prolonging the system’s
operation time is to increase the filtering area. In return lines, no
smaller depth filters than that of pore size 10 µm needs to
be used, because microbial growth improves their filtering capa-bility
even at low growth levels.
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