<div>Fluid power is widely used in a variety of applications such as construction machines, aerospace, automotive, agricultural machinery, manufacturing, etc. Although this technology has many obvious advantages such as compactness, robustness, high power density, and so forth, there is much room for improvement, of which one of the most important and challenging problems is the noise.</div><div><br></div><div>Different institutes have been researching fluid power noise for decades. However, much of the experimental investigation was based on simple measurement and analysis techniques, which left the designers/researchers no method of understanding the complicated phenomena. A microphone array is a powerful tool that unfortunately has not been introduced to the fluid power noise research. By capturing the magnitude and phase information in space, a microphone array enables the noise source identification, separation, localization and so forth.</div><div><br></div><div>This thesis focuses on implementing the microphone array processing techniques on a synthetic microphone array for fluid power noise diagnostics. Differing from traditional scan-based approaches, the synthetic array is created by synchronizing the non-synchronous measurements to achieve the equivalent effect of a multi-microphone snapshot. The final results will show the power of microphone arrays and provide an economical solution to achieve approximate results when a real microphone array is not available.</div>

Hydraulic circuits with fast dynamic response are often characterized by low power efficiency; on the other hand, energy-efficient circuits under certain circumstances, can demonstrate slow transient responses. Continuously rising energy costs combined with the demand on high performance has necessitated that hydraulic circuits become more efficient yet still demonstrate superior dynamic response. This thesis introduces a new hydraulic circuit configuration which demonstrates high dynamic performance and high efficiency. A pump-controlled hydraulic motor system was used as the basis of the study because of its high circuit efficiency. This is primarily because there is no power loss between the pump and motor. To improve the dynamic response of the pump, a DC motor was designed to control the pump swashplate (and hence flow rate) directly. The pump and DC motor were mathematically modeled and their parameters were experimentally identified. Based on the model and experimental results, a nonlinear PID controller was designed for the DC motor. By means of the DC motors quick dynamic response (in the order of 10 ms), the DC motor controlled pump demonstrated a fast dynamic response with a rise time of 15 to 35 ms depending on the pump pressure. As the dynamic response speed of the pump flow rate was increased, overshoot of the hydraulic motor output also increased. To reduce this overshoot, a bypass flow control circuit was designed to bypass part of the flow during the transient. Due to the unique operating requirements of the bypass flow control system, a PID controller with a resetable integral gain was designed for the valve to reduce the rise time of the bypass control valve. The feasibility ("proof of concept") of the bypass flow control concept was first established using simulation techniques. The simulation results showed that the bypass flow control system could significantly reduced the overshoot of the hydraulic motor rotational speed. The bypass controller was applied to the experimental test circuit. The transient results for the pump-controlled motor system with the bypass flow control are presented under a constant resistive and an inertial load. The test results showed that the bypass flow control could reduce the overshoot of the hydraulic motor rotational speed by about 50%. The relative efficiency of the circuit with the bypass flow control system was 1% to 5% lower for the particular pump-controlled system that was used in this study. For a pump/motor that does not demonstrate significant flow ripple of the magnitude experienced in this study, the relative efficiency would be the same as the pump/motor system without bypass. It was concluded that the proposed bypass control system, combined with the DC motor-swashplate driven pump, could be used to create an energy efficient circuit with excellent dynamic transient responses.

Hydraulic circuits with fast dynamic response are often characterized by low power efficiency; on the other hand, energy-efficient circuits under certain circumstances, can demonstrate slow transient responses. Continuously rising energy costs combined with the demand on high performance has necessitated that hydraulic circuits become more efficient yet still demonstrate superior dynamic response. This thesis introduces a new hydraulic circuit configuration which demonstrates high dynamic performance and high efficiency. A pump-controlled hydraulic motor system was used as the basis of the study because of its high circuit efficiency. This is primarily because there is no power loss between the pump and motor. To improve the dynamic response of the pump, a DC motor was designed to control the pump swashplate (and hence flow rate) directly. The pump and DC motor were mathematically modeled and their parameters were experimentally identified. Based on the model and experimental results, a nonlinear PID controller was designed for the DC motor. By means of the DC motors quick dynamic response (in the order of 10 ms), the DC motor controlled pump demonstrated a fast dynamic response with a rise time of 15 to 35 ms depending on the pump pressure. As the dynamic response speed of the pump flow rate was increased, overshoot of the hydraulic motor output also increased. To reduce this overshoot, a bypass flow control circuit was designed to bypass part of the flow during the transient. Due to the unique operating requirements of the bypass flow control system, a PID controller with a resetable integral gain was designed for the valve to reduce the rise time of the bypass control valve. The feasibility ("proof of concept") of the bypass flow control concept was first established using simulation techniques. The simulation results showed that the bypass flow control system could significantly reduced the overshoot of the hydraulic motor rotational speed. The bypass controller was applied to the experimental test circuit. The transient results for the pump-controlled motor system with the bypass flow control are presented under a constant resistive and an inertial load. The test results showed that the bypass flow control could reduce the overshoot of the hydraulic motor rotational speed by about 50%. The relative efficiency of the circuit with the bypass flow control system was 1% to 5% lower for the particular pump-controlled system that was used in this study. For a pump/motor that does not demonstrate significant flow ripple of the magnitude experienced in this study, the relative efficiency would be the same as the pump/motor system without bypass. It was concluded that the proposed bypass control system, combined with the DC motor-swashplate driven pump, could be used to create an energy efficient circuit with excellent dynamic transient responses.

Noise generated by fluid power applications can be treated using bladder-style suppressors, and an optimal operating condition for these devices is sought in this thesis. Bladder-style suppressors employ a compliant nitrogen-charged bladder to create an impedance change within the system, reflecting the noise back to the source and preventing it from propagating downstream. The noise in a hydraulic system is created by a pump, the flow source in a hydraulic system, and can be separated into three categories: fluid-borne noise, structure-borne noise and airborne noise. Fluid-borne noise places addition stress on sealing surfaces, potentially causing leaks. Airborne noise can be uncomfortable, even hazardous depending on the level. Bladder-style suppressors primarily treat fluid-borne noise; however, it is seen in the literature that fluid-borne noise is the cause of structure-borne and airborne noise. This thesis presents an optimization method for finding the optimal charge pressure for implementation with a given system operating over a broad range of system pressures. The optimization weights suppressor performance by the spectral content of the fluid-borne noise as well as the duty cycle of the system. A single charge pressure works well over a small range of system pressures, though many fluid power applications operate over a larger range of system pressure than the usable range of a suppressor. For systems operating over an extremely broad pressure range, two suppressors charged to different pressures are used to treat the noise in the entire system pressure range. To determine suppressor performance experimental measurements were performed, and models developed, of the transmission loss of this type of device. A multi-microphone method using transfer function relationships between six sensors determines the transmission loss of the suppressor under test. An equivalent fluid model modeling the wave behavior both upstream and downstream, as well as within the suppressor, was created to predict suppressor transmission loss. Optimal configurations are found for a set of system pressures, charge pressures and duty cycles. Analysis of the results shows the time weighting has a more significant impact on the optimum charge pressure than the frequency weighting, as shown by duty cycles considered in this thesis. In addition, all charge pressures selected as optimal for either single suppressor optimizations or double suppressor optimizations, exhibit the highest transmission loss for a single system pressure in the pressure duty cycle for a simulated machine.

Improved efficiency, better controllability and low noise are the most demanding features form a displacement machine now-a-days. Most of the conventional displacement machines are basically a reciprocating pumping element controlled by valve plates or with the help of check valve [1]. This kind of hydraulic machines loose efficiency dramatically at partial displacement because all of the pistons remain at high pressure at the cycle time and due to pressure inside the piston leakage and shear losses increases. One approach to improve the efficiency of the displacement machine can be controlling each hydraulic piston by using programmable faster valves called digital valve. As the total displacement will be controlled digitally, the total system is called Digital Displacement Technology. In digital displacement machine it is possible to disconnect some of the pistons from the load and the piston will connect only with the low pressure side, minimizing losses due to leakage and shear. As the valve will control directly with digital controller it will eliminate the necessity of servo-hydraulic control required by conventional systems. Digital valves can open fully and close again with the input signal within one revaluation of the shaft, so it gives better control to the pumping element results reduction in hysteresis and increase the linearity of the pumping element. In Digital Displacement machines by controlling the valves pistons are connected with the machine when pressure is equal, but in the traditional machines piston connection was pre-determined with the shaft angle. By doing the piston control efficiency of the machine will improve and the sound generates for the decompression flow will be reduced [17]. Also energy storage and recovery can be possible by using accumulator.

The pitch trim actuator is a hydraulic powered electro-mechanical flight control device of UH-60 helicopters which converts a mechanical input and an electrical command into a mechanical output with trim detent capabilities. In this thesis study, pitch trim actuator is investigated and a mathematical model is developed. From these mathematical equations, the actuator is modeled in MATLAB Simulink environment. While constructing the mathematical model, pressure losses in hydraulic transmission lines and compressibility of hydraulic oil are considered. To achieve a more realistic model for valve torque motor, particular tests are carried out and the torque motor current gain and the stiffness of torque motor flexure tube and the flapper displacement are obtained. Experimental data to verify the Simulink model is acquired with KAM-500 data acquisition system. A test fixture is designed for acquiring the experimental data. This test fixture can also be used to test the pitch trim actuator during depot level maintenance and overhaul. To verify the consistency of Simulink model, acquired experimental data is implemented in Simulink environment. The output of Simulink model simulation and the experimental data are compared. The results of comparison show that the model is good enough to simulate the steady state behavior of the actuator.

<p>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.</p><p>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</p><p><strong> </strong></p><p><strong>The fixed relation </strong>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.</p><p><strong> </strong></p><p><strong>The flow directions </strong>are fixed for a given spool position; therefore, no energy recuperation and/or regeneration ability is available.</p><p>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 chambers (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.</p><p>The novel system presented in this thesis needs only a position sensor on each compensator spool. This simple sensor is also suitable for identification of mode switches, e.g. between normal, differential and regenerative modes. Patent pending.</p><p>The balance of where to put the functionality (hardware and/or software) makes it possible to manoeuvre the system with maintained 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:</p><p><strong>Mode switches </strong>The mode switches are accomplished without knowledge about the pressures in the system</p><p><strong>Throttle losses </strong>With the new system approach, choice of control and measure signals, the throttle losses at the control valves are reduced</p><p><strong>Smooth mode switches </strong>The system will switch to regenerative mode automatically in a smooth manner when possible</p><p><strong>Use energy stored in the loads </strong>The load, e.g. a cylinder, is able to be used as a motor when possible, enabling the system to recuperate overrun loads</p><p>The system and its components are described together with the control algorithms that enable energy efficient operation. Measurements from a real application are also presented in the thesis.</p>

No description available.

Modeling, simulation, and optimization play vital roles throughout the engineering design process; however, in many design disciplines the cost of simulation is high, and designers are faced with a tradeoff between the number of alternatives that can be evaluated and the accuracy with which they can be evaluated. In this thesis, a methodology is presented for using models of various levels of fidelity during the optimization process. The intent is to use inexpensive, low-fidelity models with limited accuracy to recognize poor design alternatives and reserve the high-fidelity, accurate, but also expensive models only to characterize the best alternatives. Specifically, by setting a user-defined performance threshold, the optimizer can explore the design space using a low-fidelity model by default, and switch to a higher fidelity model only if the performance threshold is attained. In this manner, the high fidelity model is used only to discern the best solution from the set of good solutions, so that computational resources are conserved until the optimizer is close to the solution. This makes the optimization process more efficient without sacrificing the quality of the solution. The method is illustrated by optimizing the trajectory of a hydraulic backhoe. To characterize the robustness and efficiency of the method, a design space exploration is performed using both the low and high fidelity models, and the optimization problem is solved multiple times using the variable fidelity framework.

Condition monitoring of systems and detection of changes in the systems are of significant importance for an automated system, whether it is for production, transport, amusement, or any other application. Although condition monitoring is already widely used in machinery, the need for it is growing, especially as systems become increasingly autonomous and self-contained. One of the toughest tasks concerning embedded condition monitoring is to extract the useful information and conclusions from the often large amount of measured data. The use of self-organising maps, SOMs, for embedded condition monitoring is of interest for the component manufacturer who lacks information about how the component is to be used by the system integrator, or in what applications and load cases. At the same time, there is also a potential interest on the part of the system builders. Although they know how the system is designed and will be used, it is still hard to identify all possible failure modes. A component does not break at all locations or in all functions simultaneously, but rather in one, more stressed, location. Where is this location? Here, the collection of as much data as possible from the system and then processing it with the aid of SOMs allows the system integrators to create a map of the load on the system in its operating conditions. This gives the system integrators a better chance to decide where to improve the system. Automating monitoring and analysis means not only being able to collect prodigious amounts of measured data, but also being able to interpret the data and transform it into useful information, e.g. conclusions about the state of the system. However, as will be argued in this thesis, drawing the conclusions is one thing, being able to interpret the conclusions is another, not least concerning the credibility of the conclusions drawn. This has proven to be particularly true for simple mechanical systems like pneumatics in the manufacturing industry.