PhD-Theses
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Awards 
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PHDS, HABILITATIONS, AWARDS AND BOOKS


From Editor

Through the listing of PhD theses and habilitations world-wide completed, books published as well as prizes awarded, the International Journal of Fluid Power strives to keep its readers informed of new literature and scientific works. Names of authors, title, number of pages, publisher, ISBN, date, abstract and in case of PhD theses, name of university and institute are desired. The abstract should not exceed 200 words. The Journal solicits your help in keeping the listing current by asking you to transmit conference and meeting information formally or informally by post, fax or email to Dr. Monika Ivantysynova, MAHA Professor Fluid Power Systems, Purdue University, College of Engineering, 225 South University Street, West Lafayette, IN 47907, USA, Phone: +01 765 742 - 1213, Fax: +01 765 742 - 1217, Email: Mivantys@purdue.edu

PhD-Theses completed in 2007

Björn Eriksson

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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Norbert Gstöttenbauer

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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Jonathan Haynes

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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Achim Helbig

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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Richard Elliott

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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Hannu Riipinen

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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