A new camless electrohydraulic valve train concept for combustion engines was developed at Empa (Swiss Federal Laboratories for Materials Science and Technology, Dübendorf, Switzerland) and tested on a spark ignition passenger car engine. Besides full flexibility with regard to lift and timing of the engine gas exchange valves it features robustness, simplicity and in particular a low own drive power need due to a maximum of hydraulic energy recuperation. The engine test results confirm substantial efficiency gains in classical as well as in hybrid power trains while also maintaining additional advantages. The system also has the potential to become a key element for load control of piston based compressors and expanders, reciprocating Joule Cycle engines and derivable future electricity storage systems.

This paper presents a conceptual study aiming to improve the compactness of electro-hydraulic compact drives (ECD ). In most current ECD architectures, gas accumulators are used as volume compensators for the flow imbalance emerging whenever asymmetric single rod cylinders are used. To stay within a required reservoir pressure range typically from two to four bar, a large gas volume is required, compromising system compactness. Combining conventional ECD architectures with a bootstrap reservoir offers a greater degree of freedom in system design, which enables downsizing or avoidance of the gas volume. Another potential benefit by including a bootstrap reservoir is the possibility of elevating the backpressure of the ECD thus enhancing drive stiffness, expanding the application range and market acceptance. Based on an open analysis of the solution space occurring when introducing a bootstrap reservoir, three system architectures are selected for a conceptual study. The results show that the downsizing potential is strongly dependent on the maximum friction force and the area ratio of the bootstrap reservoir pistons, while a linear analysis reveals that for some system architectures the bootstrap reservoir may severely influence the system dynamics. Simulation results confirm the functionality of the proposed system architectures, and show that a potential for downsizing/avoiding the gas volume, as well as increasing the ECD stiffness is present.

This paper discusses the potential of centralized or decentralized electro-hydraulic (EH)-drives in comparison to conventional hydraulic systems. The systems are presented in diagrams covering the major electric and hydraulic components for an exemplary application, but also include specific technical data like the sizing of the components according to power, pressure, rotational speeds etc. In a second step, all systems are compared and evaluated based on criteria like design effort, energy saving potential, controllability, and servicing and maintenance of the machine. The resulting effects on fuel consumption are summarized as well. Finally, an evaluation of the potential of EH-drives in construction machinery and a derivation of the demands for future customization of electro-hydraulic linear drives is given on the basis of a SWOT-analysis from the point of view of a construction machinery OEM.

Animals exploit soft structures to move smoothly and effectively in complex natural environments. These capabilities have inspired robotic engineers to incorporate soft actuating technologies into their designs. Developing soft muscle-like actuation technology is one of the grand challenges in the creation of soft-body robots that can move, deform their body, and modulate body stiffness. This paper presents the development of smart pneumatic McKibben muscles woven and reinforced by using conductive insulated wires to equip the muscles with an inherent sensing capability, in which the deformation of the muscles can be effectively measured by calculating the change of wire inductance. Sensing performance of a variety of weaving angles is investigated. The ideal McKibben muscle models are used for analysing muscle performance and sensing accuracy. The experimental results show that the contraction of the muscles is proportional to the measured change of inductance. This relationship is applied to a PID control system to control the contraction of smart muscles in simulation, and good control performance is achieved. The creation of smart muscles with an inherent sensing capability and a good controllability is promising for operation of future soft robots.

Magnetic Shape Memory (MSM) alloys show a superelastic behaviour with possible deformation rates up to 6% until 12% and a sufficient lifetime performance [1, 2]. In this paper, a passive application for a superelastic Ni-Mn-Ga-alloy is presented by using the MSM element as an accurately defined inner friction in a system of a multistable actuator, in particular a multistable proportional valve. The multistable valve is characterized by a currentless holding of the valve displacement in any position of the stroke. This circumstance makes the concept a very low energy consumption valve, compared to conventional proportional valves with solenoid actuators. The new aspect of a rigid connection of MSM Materials enables an absorption of tension as well as compressive forces. To realize an applicable controlling valve, a simple and effective controlling strategy has been implemented. Due to the stabilizing effect of the MSM element, an accurate controlling of the valve stroke and the usage for example as a pressure-, mass-flow or temperature-controlling valve was made possible. Furthermore, some potential applications in pneumatics as well as in hydraulics are presented.

In the automotive industry, the Safety Function-FMEA according to ISO 26262 and its application to functional safety relevant systems is a well-established process in the form of Automotive Safety Integrity Levels (ASILs). These represent the failure mitigation that must be applied to ensure an acceptable residual risk of malfunctioning behaviour. The DIN EN ISO 13849 (ISO 13849) already describes a process to reduce risks for machines which starts with a Hazard And Risk Analysis (HARA) as described in DIN EN ISO 12100 and concludes with the Safety Requirements Specification (SRS). The SRS is a functional and technical safety concept defining requirements and guidelines to make sure the design conforms to defined safety goals. ISO 13849 lists important faults and failures for various technologies. The defined Safety Functions (SFs) can be classified in corresponding categories that lead to the particular hardware/system structure. This applies to mechatronic systems consisting of at least one sensor, one control unit and one actuator to monitor the system and effect a response in case of failure. Compared to the methods described in ISO 13849, the Safety Function-FMEA allows systematic identification of additional failures resulting from combinations of effects, rather than only listing the main failure causes. Based on the complexity of the machines it is highly recommended to perform a Safety Function-FMEA as a complementary method to assess and improve the overall safety of machinery.

<p>One of the most often utilized machinery in fluid power applications is the material-handling machines, which includes telehandlers, forklifts, cranes, and scissor lifts that are used from constructions to mining.<br> Counterbalance valves (CBVs), hydraulic components that protect the system from failures and manage the load under overrunning load conditions due to their distinctive design, are used in material-handling devices to ensure both the operators' and most off-road vehicles' safety. However, they present a significant shortcoming: the over-pressurization of the supply line, which leads to constringent energy consumption. The primary motivation for this work is this drawback. In this work, a CBV-based system with an adjustable pilot has been investigated using a truck-mounted hydraulic crane as a reference machine.</p> <p>By analyzing theoretically and experimentally the behavior of this novel hydraulic system, it is possible to achieve up to 90% of energy-saving than a baseline configuration of a load-holding machine by controlling the opening of the CBV by adjusting the pressure at the pilot stage. After exploring the capabilities of the studied system and the possible control strategies to control opening of the CBV, this work suggests two different solutions to control the system: “Smart CBV” and “Smart System” modes. By properly controlling the signal on the pilot stage of the CBV, "Smart CBV" enables energy savings of up to 80%. On the other hand, the "Smart System" mode can save up to 95% of energy by using the CBV as a meter-out element that successfully regulates the flow to the actuator and, consequently, its velocity. To attain these outstanding results, it is essential to maintain proper system control.</p> <p>Moreover, since safety is one of the priorities of this type of machine, a Condition Monitoring (CM) model is developed to ensure the actual functionalities of the novel proposed system. By identifying faulty conditions and preventing breakdowns before they occur, CM can be utilized to improve the safety of these type of machines. However, training a CM model using experimental data is time-consuming and expensive since it requires abundant data with different extent of machine failures from the field test. The solution suggested in this work is to generate faulty and healthy data for the reference machine using a high-fidelity simulation tool to train a CM model.</p> <p>Particular focus is given to the counterbalance valve (CBV), a crucial element for the hydraulic system of material handling machines, and the linear actuator (hydraulic cylinder). The different types of faults on two elements are modeled with an approach validated using experimental tests. Considering that the simulation model provides comparable outcomes to training on empirical data, the CM model is trained in a single fault condition and multi faults conditions using simulated data. Instead, the CM model is tested using the experimental tests in multiple faulty conditions on the chosen components.</p> <p>Moreover, finding the best CM model for this case study is another goal of this work. As a result, several CM models are investigated: Random Forest (RF), K-Nearest Neighbor (KNN), and Support Vector Machine (SVM). In terms of precision and recall, metrics frequently employed in the CM field to assess the performances of the designed CM model, the results generally indicate more than 90% accuracy.</p>

The existence of hydrodynamically developed, laminar Viscoelastic Secondary Flows (VSFs) of non-Newtonian fluids in straight ducts of non-circular cross-section was proposed in the 1950's. VSFs have since been observed sporadically, and only once with a velocimetric technique. Using axial and transverse full flow-field velocity-position raster maps made with Rheological Nuclear Magnetic Resonance (Rheo-NMR), Newtonian and non-Newtonian fluid flows were quantified in Hagen-Poiseuille and Power Law contexts, over more than two orders of magnitude of flow rate, in ducts of circle, square, triangle, and pentagon cross-section. VSF was reliably and repeatedly observed to occur at between one part in 130 and one part in 600 of the primary axial flow velocity. Velocity measurements ranged from <10 µm/s to approximately 30 cm/s, suggesting a velocity dynamic range >3E4 without optimization. To obtain VSF flow direction information, a novel flow directional phantom was developed and characterized. Aqueous solutions of Polyethylene Oxide (PEO), Viscarin GP-109NF, Viscarin GP-209NF (V209), Hyaluronan (HA) in a Phosphate-Buffered Saline-like solvent, and an aqueous Polyethylene Glycol/PEO-based Boger fluid were investigated. Axial data was corroborated with related data gathered by an independent method. Basic simulations corroborated the VSF observations. Duct hydraulic diameters (>= 1.6 mm) approached the micro-channel regime. VSF detections in HA --- synovial fluid's principal component --- and V209 were novel, as were observations of some artifacts which were subsequently characterized and corrected. The detection of VSF in HA represents the first experimental evidence suggesting that its second normal stress (N_2) is comparable to that of better-characterized fluids. In the first application of a new VSF-based method, a particular Boger fluid's constant viscosity and, in the square duct, its lack of VSF were used with established criteria to suggest that the fluid's N_2 approached zero. The development of a rudimentary, but versatile and inexpensive home-built velocimetric spectrometer is detailed, as are several new components. An exhaustive VSF literature review is included. The remarkable transverse velocimetric ability of Rheo-NMR in both optically opaque and transparent system is highlighted, suggesting that perhaps the technique might represent, in both micro-channels and conventional ducts, the gold-standard in flow velocimetry.

Increased oil prices and environmental issues have increased a need of loweringthe emissions from and the fuel consumption in heavy construction machines. Anatural solution to these issues is a lowered input power through downsizing ofthe engine. This implies a demand on higher transmission efficiency, in order tominimize the intrusion on vehicle performance. More specifically, alternatives tothe conventional torque converter found in heavier applications today, must beinvestigated. One important part of this is the task of controlling the transmissionwithout jeopardising the advantages associated with the torque converter, such asrobustness and controllability.In this thesis, an alternative transmission concept for a backhoe loader is investigated.The studied concept is referred to as a 2-mode Jarchow power-splittransmission, where a mechanical path is added to a hydrostatic transmission inorder to increase transmission efficiency. The concept is evaluated in computerbased simulations as well as in hardware-in-the-loop simulations, where a physicalhydrostatic transmission is exposed for the loads caused by the vehicle duringvarying conditions. The loads are in turn simulated according to developed modelsof the mechanical parts of the vehicle drive line.In total, the investigated concept can be used instead of the torque converterconcept, if the hydrostatic transmission is properly controlled. The results alsoshow that there is a high possibility that the combustion engine in the backhoeloader can be downsized from 64 kW to 55 kW, which would further increase thefuel savings and reduce the emissions.

We are pleased to present the conference proceedings for the 12th edition of the International Fluid Power Conference (IFK). The IFK is one of the world’s most significant scientific conferences on fluid power control technology and systems. It offers a common platform for the presentation and discussion of trends and innovations to manufacturers, users and scientists. The Chair of Fluid-Mechatronic Systems at the TU Dresden is organizing and hosting the IFK for the sixth time. Supporting hosts are the Fluid Power Association of the German Engineering Federation (VDMA), Dresdner Verein zur Förderung der Fluidtechnik e. V. (DVF) and GWT-TUD GmbH. The organization and the conference location alternates every two years between the Chair of Fluid-Mechatronic Systems in Dresden and the Institute for Fluid Power Drives and Systems in Aachen. The symposium on the first day is dedicated to presentations focused on methodology and fundamental research. The two following conference days offer a wide variety of application and technology orientated papers about the latest state of the art in fluid power. It is this combination that makes the IFK a unique and excellent forum for the exchange of academic research and industrial application experience. A simultaneously ongoing exhibition offers the possibility to get product information and to have individual talks with manufacturers. The theme of the 12th IFK is “Fluid Power – Future Technology”, covering topics that enable the development of 5G-ready, cost-efficient and demand-driven structures, as well as individual decentralized drives. Another topic is the real-time data exchange that allows the application of numerous predictive maintenance strategies, which will significantly increase the availability of fluid power systems and their elements and ensure their improved lifetime performance. We create an atmosphere for casual exchange by offering a vast frame and cultural program. This includes a get-together, a conference banquet, laboratory festivities and some physical activities such as jogging in Dresden’s old town.:Group 8: Pneumatics Group 9 | 11: Mobile applications Group 10: Special domains Group 12: Novel system architectures Group 13 | 15: Actuators & sensors Group 14: Safety & reliability