To minimize the complexity of existing process control valves, the authors derived a new control valve design by functional separation and functional integration of functions. One key element of this new valve design is the functional integration of teh actuator into the valve´s throttle. A hydraulic swivel motor is operated with the process fluid, in this case water. The pressure difference to operate the motor comes from the valve itself. Within this paper we present the control valve design and show in detail how we used the Fail-Early design method to develop the hydraulic swivel motor. The construction is discussed using the experience from manufacturing the prototype and the first exp erimental results are shown. The experiments yield, that the swivel motor principle is promising. Finally, the next development issues are discussed.

Two - stage servovalves, despite being widely used in aircraft and industry because of their reliability and high performance, have a few disadvantages that are still unsolved at the state of the art, such as the power consumption caused by the quiescent flow (internal leakage) in the pilot stage, and the complexity and high number of parts of the torque motor assembly of the pilot stage. The solution to these problems can help to reduce costs, weight, power consumption, and to enhance the reliability and producibility as well as the performance of these valves. This paper presents a novel configuration of servovalve, which has the potential to overcome the above-mentioned issues. The proposed servo-valve includes a novel architecture for the pilot stage by using two piezo-electric actuators (ring benders). In this paper, the performance of this novel pilot stage is assessed. To this end, a valve prototype has been constructed and tested; the experimental results are also used to validate a numerical model obtained with the software Simscape Fluids. The results show that, acting on specific parameters, the performance of the piezo-valve can be very competitive, while ensuring very low internal leakage and complexity.

In this paper, a new methodology is presented to estimate the lifetime impact of design changes, called Failure Likelihood Assessment (FLA). The discussion in this paper is on the fatigue lifetime prediction of axial piston units, especially after a design change. The demonstration object is an axial piston pump due to extreme environmental conditions and high specification demands, where the FLA is applied to a manufacturing change in an existing product and delivers an effect on the unit reliability. The resulted reliability imp rovement, if combined with typical calculation methods like Weibull analysis, delivers an increase in predicted lifetime considering the intended modification. As demonstration subje ct, a change of the manufacturing process of the cylinder block hub in an axial piston pump is used. The effect to the lifetime is predicted via the FLA-method and the results are calculated with test data and compared to theoretical results. The paper shows that the methodology delivers highly accurate results providing that the FLA is a powerful tool to analyze design changes as weil as new designs in regard to reliability and lifetime. The benefit for the user of this methodology will hence be more reliable products with optimized designs tobest fulfil customer's performance requirements.

This paper describes the failure detection system of an electro-hydraulic actuator with dual modular redundancy based on a hybrid twin TM concept. Hybrid twin TM is a combination of virtual twin that operates in parallel with the actuator and represents its ideal behaviour, and a digital twin that identifies possible failures using the sensor readings residuals. Simulation-based system reliability analysis helps to generate a dataset for training the digital twin using machine learning algorithms. A systematic failure detection approach based on decision trees and the process of analysing the quality of the result is described.

Eaton created a new safety controller architecture to allow our customers to design implement, verify and maintain a SIL-2 safety certified application for compliance with IEC 61508:2010 and ISO 13849 Functional Safety Standards. The new architecture has been implemented in a line of safety controllers SFX12 and SFX20 that extend the line of existing mobile controllers HFX12 to HFX48. The new controllers are targeted for controlling mobile and stationary machine applications with focus on steer by wire and propel by wire.

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 1 | 2: Digital systems Group 3: Novel displacement machines Group 4: Industrial applications Group 5: Components Group 6: Predictive maintenance Group 7: Electro-hydraulic actuators / Der Download des Gesamtbandes wird erst nach der Konferenz ab 15. Oktober 2020 möglich sein.:Group 1 | 2: Digital systems Group 3: Novel displacement machines Group 4: Industrial applications Group 5: Components Group 6: Predictive maintenance Group 7: Electro-hydraulic actuators

Different special brass (e.g. CuZn37Mn3Al2PbSi) and bronze alloys (e.g. CuPb15Sn) are well known for use in oil-hydraulics having in common to be alloyed with lead. The lead content of special brass alloys in this use ranges from 0.1 to 2.0 mass-%. Some bronze alloys provide even much higher contents of lead of 10 to 15 mass-%. Typically, lead is considered for improvement of machinability or castability. Beyond this purpose lead in brass and bronze alloys affects many more properties of manufacturing and application. During the shaping of the parts by means of hot or cold forming often the materials are strained close to their limits. Thanks to lead cracking is prevented during this process. Lead is also of great importance for the improvement of tribological systems. The surfaces of these systems are exposed to friction and wear. Lead is incorporated in the surface layers and supports the tribological system in their running-in process to achieve a steady state of friction and wear. Above all lead is unique because it forms no solid solution with copper or brass and forms no compounds with other typical copper alloying elements. The feasibility assessment of elements in order to substitute lead in brass or bronze alloys has to be done for each alloy and application individually. In oil-hydraulic applications as bushings, slippers or distributor plates, lead-free alloys must fulfil different profiles of requirements, depending on the conditions of manufacturing and application. The requirements do not only include mechanical strength, formability and thermal strength, but also fatigue strength, low friction and high wear resistance and lubricant compatibility. Consequently, the substitution of lead in brass and bronze alloys for application in oil-hydraulics is a challenging task. This does not only apply for the requirements for machining and forming, but particularly for the need of the new alloys to function under wear, friction and corrosion. Examples are given for how these challenges of new lead-free special brass alloys can be met in bushings (machining, friction properties), slippers (forming, strength) and distributor plates (fatigue strength) for axial piston pumps. Further on, new lead-free special brass alloys for contact with environmentally compatible lubricants are presented. All these examples show that there is not the one and only lead-free alloy for applications in oil-hydraulics. In fact, every application requires a different alloy which is composed and processed individually to meet the specific demands.

Tribology has been recognized as a very important discipline in different branches of industry because almost every mechanical system has some moving parts. Due to the relative motion between these different mechanical parts, a variety of contacts are formed, and they are very often lubricated with oil. Environmental protection and ecological awareness are becoming increasingly important, which in turn has resulted in the shift to a low-carbon society, making water more interesting as a possible lubricant. On the one hand, water is less environmentally damaging as a lubricant than oil, but on the other hand, water has very poor lubrication properties, as its viscosity is 100 times lower than the viscosity of oil. These limitations might be overcome by appropriate surface engineering (e.g., diamond-like carbon, DLC). Tribological tests were performed in oil and water for two different contacts. Steel/steel and steel/DLC were investigated. DLC was recognized as a very promising solution, which ensures low friction and low wear. DLC was deposited on a real hydraulic part in an orbital hydraulic motor and tested under real industrial conditions. The overall efficiency of the hydraulic motor was measured.

The efficiency of hydraulic drive systems in mobile machines is influenced by several factors, like the operators’ guidance, weather conditions, material respectively loading properties and primarily the working cycle. This leads to varying operation points, which have to be performed by the drive system. Regarding efficiency analysis, the usage of standardized working cycles gained through measurements or synthetically generated is state of the art. Thereby, only a small extract of the real usage profile is taken into account. This contribution deals with process pattern recognition (PPR) and frequency based efficiency evaluation to gain more precise information and conclusion for the drive design of mobile machines. By the example of an 18 t mobile excavator, the recognition system using Hidden – Markov - Models (HMM) and the efficiency evaluation process by means of backwards simulation of measured operation points will be described.

A new primary torque control concept for hydrostatics mobile machines was introduced in 2018 [1]. The mentioned concept controls the pressure in a closed circuit by changing the angle of the hydraulic pump to achieve the desired pressure based on a feedback system. Thanks to this concept, a series of advantages are expected [2]. However, while working in a Y cycle, the primary torque controlled wheel loader has worse performance in efficiency compared to secondary controlled earthmover due to lack of recuperation ability. Alternatively, we use deep learning algorithms to improve machines’ regeneration performance. In this paper, we firstly make a potential analysis to show the benefit by utilizing the regeneration process, followed by proposing a series of CRDNNs, which combine CNN, RNN, and DNN, to precisely detect Y cycles. Compared to existing algorithms, the CRDNN with bidirectional LSTMs has the best accuracy, and the CRDNN with LSTMs has a comparable performance but much fewer training parameters. Based on our dataset including 119 truck loading cycles, our best neural network shows a 98.2 % test accuracy. Therefore, even with a simple regeneration process, our algorithm can improve the holistic efficiency of mobile machines up to 9% during Y cycle processes if primary torque concept is used.