This paper examines the model-based design of thermal systems in mobile machines with a focus on heat exchanger design. An industry project is described in which the vapor compression cycle for the air-conditioning system was modeled using the software SimulationX. By modeling heat exchanger sections separately, multiple flow arrangements could be tested without the need for physical prototypes. The paper presents this work in the context of the full model-based design process including extensions for hardware in the loop (HiL) testing of control units and operator training using virtual machines.

Hydraulic tanks have a variety of different tasks. The have to store the volume of oil needed for asymmetric actors in the system as well as to supply the system with preconditioned oil. This includes the deaeration as air contamination is affecting the overall system performance. The separation of the air in the tank is being realized mainly by passive methods, improving the guidance of the air and oil flow. The use of CFD models to improve the design of hydraulic tank is recently often discussed. In this paper, a design method for hydraulic tanks using CFD is presented and discussed. First the different requirements on a hydraulic tank are described as well as the motivation changing the tank designs. Additionally, a quick overview on different calculation models for the behavior of air in oil as well as the capabilities of CFD to reproduce them is given. After this the methodology of tank design applying CFD is presented. The method is then used in an example.

Modern production systems have to allow high performance cutting processes in a flexible production system environment at a high level of accuracy. The final workpiece accuracy is mainly influenced by the thermo-elastic behavior of the machine tool and can be improved by additional measures, compensation strategies and an optimized machine design. These measures are often implemented as stand-alone solutions. According to the Industry 4.0 all information should be connected in a single model of the actual machine state to increase machining accuracy. It is therefore necessary to integrate upcoming smart fluid power systems into the machine network.

Controlling the thermo-elastic behavior of tooling machines can only be achieved by systematic analysis, characterization and design of their fluidic system. In the first stage of this project, fundamental work was done to develop simulation methods for the calculation of the thermodynamic behavior of a representative example of a milling machine and each of its components. With experimental and numerical data it was proven, that significant improvement can be achieved by a proper design of heat transfer conditions of the fluidic system. To correct and counterbalance thermo-energetic effects, it will be necessary to develop new structures of the tooling machines systems which ensure the temperature-control of local subsystems in dependence of the actual working process. The work which is documented in this paper deals with the thermodynamic behavior of the motor spindle.

In pneumatic pressure control applications the influence of tubes that connect the valve with the control volume ist mainly neglected. This can lead to stability and robustness issues and limit either control performance or tube length. Modeling and considering tube behavior in controller design procedure allows longer tubes while maintaining the required performance and robustness properties without need for manual tuning. The author\'s previously published Simplified Fluid Transmission Line Model and the proposed model-based controller design enable the specification of a desired pressure trajectory in the control volume while the pressure sensor is mounted directly at the valve. Thus wiring effort is reduced as well as cost and the chance of cable break or sensor disturbance. In order to validate the simulated results the proposed control scheme is implemented on a real-time system and compared to a state-of-the-art pressure regulating valve

Modern production systems have to allow high performance cutting processes in a flexible production system environment at a high level of accuracy. The final workpiece accuracy is mainly influenced by the thermo-elastic behavior of the machine tool and can be improved by additional measures, compensation strategies and an optimized machine design. These measures are often implemented as stand-alone solutions. According to the Industry 4.0 all information should be connected in a single model of the actual machine state to increase machining accuracy. It is therefore necessary to integrate upcoming smart fluid power systems into the machine network.

In pneumatic pressure control applications the influence of tubes that connect the valve with the control volume ist mainly neglected. This can lead to stability and robustness issues and limit either control performance or tube length. Modeling and considering tube behavior in controller design procedure allows longer tubes while maintaining the required performance and robustness properties without need for manual tuning. The author\'s previously published Simplified Fluid Transmission Line Model and the proposed model-based controller design enable the specification of a desired pressure trajectory in the control volume while the pressure sensor is mounted directly at the valve. Thus wiring effort is reduced as well as cost and the chance of cable break or sensor disturbance. In order to validate the simulated results the proposed control scheme is implemented on a real-time system and compared to a state-of-the-art pressure regulating valve

This paper examines the model-based design of thermal systems in mobile machines with a focus on heat exchanger design. An industry project is described in which the vapor compression cycle for the air-conditioning system was modeled using the software SimulationX. By modeling heat exchanger sections separately, multiple flow arrangements could be tested without the need for physical prototypes. The paper presents this work in the context of the full model-based design process including extensions for hardware in the loop (HiL) testing of control units and operator training using virtual machines.

Hydraulic tanks have a variety of different tasks. The have to store the volume of oil needed for asymmetric actors in the system as well as to supply the system with preconditioned oil. This includes the deaeration as air contamination is affecting the overall system performance. The separation of the air in the tank is being realized mainly by passive methods, improving the guidance of the air and oil flow. The use of CFD models to improve the design of hydraulic tank is recently often discussed. In this paper, a design method for hydraulic tanks using CFD is presented and discussed. First the different requirements on a hydraulic tank are described as well as the motivation changing the tank designs. Additionally, a quick overview on different calculation models for the behavior of air in oil as well as the capabilities of CFD to reproduce them is given. After this the methodology of tank design applying CFD is presented. The method is then used in an example.

Controlling the thermo-elastic behavior of tooling machines can only be achieved by systematic analysis, characterization and design of their fluidic system. In the first stage of this project, fundamental work was done to develop simulation methods for the calculation of the thermodynamic behavior of a representative example of a milling machine and each of its components. With experimental and numerical data it was proven, that significant improvement can be achieved by a proper design of heat transfer conditions of the fluidic system. To correct and counterbalance thermo-energetic effects, it will be necessary to develop new structures of the tooling machines systems which ensure the temperature-control of local subsystems in dependence of the actual working process. The work which is documented in this paper deals with the thermodynamic behavior of the motor spindle.