Rund 70 % der Energieaufnahme von elektrischen Antriebssystemen wird von quasistationären Antrieben in Transportanlagen hervorgerufen. Eine gesteigerte Energieeffizienz führt neben reduzierten Energiekosten zu weiteren Nutzeffekten, wie z.B. einem verringerten Kühlaufwand, einem kleinerem Bauraum und einer höheren Lebensdauer der Komponenten. Zur Steigerung der Energieeffizienz dieser Transportanlagen werden in dieser Arbeit Methoden zur Auslegung der zugehörigen Antriebssysteme unter besonderer Berücksichtigung des Förderprozesses erarbeitet. Als repräsentative Transportanwendungen werden Pumpen- und Förderbandanlagen untersucht. Dabei wird das gesamte elektromechanische System analysiert, um das volle Energiesparpotenzial zu erfassen – beginnend mit dem Lastprofil des transportierten Förderguts bis hin zur elektrischen Energieversorgung. Hierzu werden alle Systemkomponenten modelliert, um die Verluste in verschiedenen Betriebspunkten im Volllast- und Teillastbereich abzuschätzen. Darauf aufbauend erfolgt die Erarbeitung praktikabler Projektierungshinweise und prozessspezifischer Auswahldiagramme, welche eine schnelle Vorauswahl der energieeffizientesten Antriebstopologie ermöglichen. Da die Verlustmodelle auf frei zugänglichen Datenblattangaben basieren, können die vorgestellten Methoden und Auswahlkriterien bereits in einem frühen Projektierungsstadium zur Auslegung einer energieeffizienten Transportanlage angewandt werden.

Solar Bora AB is a Linköping based company that provides end to end solution for clean and reliable energy. System developed by them generates high power 230V AC to run electrical appliances. The system consist of string of batteries which are charged by rooftop solar cells and the energy stored in the batteries is converted to AC to provide a grid voltage like experience even though the system is not connected to a grid. Energy stored in the batteries need to be converted from DC to AC efficiently. Inverter used for conversion should be efficient enough to reduce losses. This master thesis deals with optimization and Up-gradation of Half-Bridge inverter board so that switching loss can be minimized to increase efficiency. Initial part of the thesis involves investigation of different parameters which contribute to losses in inverter. Based on that some improvements were suggested in existing design of half-bridge board. Another task involved in the thesis was complete re-design of half-bridge. More efficient and robust components were selected for complete re-design. Based on new components and its specifications a new circuit and PCB was designed in Altium Designer. Lab testing was performed to verify the functionality of new Half-bridge.

Auf Grund wachsender Nachfrage der simulativen Beurteilung von Getrieben hinsichtlich Geräuschentwicklung, Vibration und Belastbarkeit, kommt den Berechnungsmethoden immer größere Bedeutung zu. Hier spielen nicht nur die Steifigkeit der Verzahnung, sondern auch die Steifigkeiten der Wellen, Lagerungen und Gehäuse eine wichtige Rolle. Dazu werden unterschiedliche Simulationsmethoden vorgestellt und diese hinsichtlich Genauigkeit, Effizienz und Limitierung bewertet. Ein wichtiger Aspekt ist in diesem Zusammenhang auch die Modellbildung, insbesondere die Ermittlung der Eingabedaten für die Beschreibung der einzelnen Komponenten und deren Verbindungselemente. Die Koppelung des Mehrkörpersystems mit einem speziellen Auslegungstool für Getriebekomponenten ist neben der Multi-Physics-Simulation und der klassischen Mehrkörperdynamik eine Methode, die die Stärken beider Tools verbindet.

This thesis presents two transient models for a prototype integrated charger for use in a plug-in hybrid-electrical vehicle application. The models can be useful in order to develop control algorithms for the system or to recommend improvements to the machine design. A flux map based method, obtaining input data from simulations using the finite element method (FEM) is used to model the grid synchronization process. The grid side voltage can then be predicted by incorporating spatial flux linkage harmonics. The model is implemented in Matlab/Simulink and compared to stand alone FEM simulations with good agreement. The charging process is modeled using an inductance based model also requiring FEM simulations as input data. Since the flux linkages in the grid and inverter side windings are dependent on each other, the presented transient model is linearized around a specific operating point. This model is also implemented in a Matlab/Simulink environment. Sensorless control of a PMSynRel drive is also studied in this thesis. Focus is put on operating limits due to magnetic saturation when operating at low speeds. The rotating and pulsating voltage vector injection methods for sensorless control are studied in detail. A technique to map the feasible sensorless control region is proposed which utilizes the resulting position error signal rather than data of differential inductances. This technique is implemented experimentally and compared to corresponding FEM simulations with good agreement. The impact of spatial inductance harmonics on the quality of the position estimates is also studied. A method to predict the maximum position estimation error due to the inductance harmonics is proposed based on simplified analytical models. A technique is presented and experimentally verified which can compensate for this effect by injecting a modified rotating voltage carrier. Lastly, the impact of saturation in the rotor structure on the initial magnet polarity detection is investigated. The experimental results, in good agreement with the corresponding FEM simulations, indicate that the impact of saturation in the magnet bridges of rotor is the dominant phenomenon at lower peak current magnitudes. / QC 20110928

The use of variable frequency drives in centrifugal pump applications has raised the question of how to select a drive. Clogging obstacles in waste water applications create unknown transient loads for the pump system. A sudden load increase occurrence can clog the pump if the drive cannot supply enough current to reach the motor’s torque demand. In order to select a suitable drive, an empirical approach has been implemented, investigating three different drives. Results have shown that selecting a drive with the highest possible overload capabilities, even if for a short time is most suitable. Operation in vector speed control gives the most reliable operation if an automatic parameter tuning is performed by the drive. / Användningen av frekvensomriktare i centrifugalpumpar har väckt fr ågan om hur en omriktare skall väljas. Igensättande objekt i avloppsvatten kan ge upphov till transienta laster i pumpsystemen. En oförutsedd lastökning kan sätta igen pumpen om frekvensomriktaren inte kan förse motorn tillräckligt med ström för att möta momentbehovet. För att välja en lämplig omriktare har ett empiriskt tillvägag ångssätt valts i en undersökning av tre olika omriktare. Resultat har visat att det är lämpligast att välja en omriktare med högst överbelastningskapacitet, även om under en kort tid. Vektor hastighetskontroll är metoden som ger stabil körning om omriktaren f ått automatiskt ställa in motorparametrarna.

This paper discusses an investigation on a novel hydraulic pump concept. The idea aims on a pump principle to be directly connected to high-speed electric motors to build compact high-pressure drives. The pump can theoretically work without solid contact and has no kinematic pulsation. The composition of the pump is basically similar to cylindrical journal bearings. In general, a journal bearing is used to support external loads on a rotating shaft. When the shaft rotates with the loads, hydrodynamic fluid force is generated in the fluid film, which compensates the external force and reduces an eccentricity of the shaft. The difference of the introduced pump concept from the bearing is that the eccentricity is fixed and it has an outlet port at the high pressure area, through which the fluid can be transferred. To examine the functionality of the pump, a test bench is constructed and experiments are performed to investigate the pressure build-up and discharging flow of the pump concept. The experimental results are numerically analyzed by using elasto-hydrodynamic lubrication (EHL) simulation, based on the 2D Reynold’s equation. From these results, the functionality of the pump concept is confirmed. Moreover, several variables that influence the characteristic curve of the pump are studied. Based on these results, geometric parameters of the test pump are redesigned to discharge sufficient flow rate for usage as commercial pumps.

There is a lot of gravitational potential energy waste when hydraulic excavators work, which seriously affects the efficiency of the whole machine and produces a large amount of emissions. In order to reduce the energy consumption and emissions of large hydraulic excavators which the boom is driven by two hydraulic cylinders, an integrated drive and potential energy recuperation principle is proposed. In the implementation, the original two-chamber hydraulic cylinders are replaced by three-chamber hydraulic cylinders with energy storage chambers, and the energy storage chambers are directly connected with the hydraulic accumulator. The dead weight of the working device is balanced by the initial hydraulic pressure of the hydraulic accumulator, and the gravitational potential energy is directly recuperated. A digital prototype is established for the simulation work to verify the energy-saving effect. Then a test prototype is constructed according to the simulation work. The standard 90° loading duty cycle tests show that compared with the standard hydraulic excavators of the same type, in the case of meeting the same digging force, the working efficiency of the excavator increases by 20.7% and the fuel consumption decreases by 17.1%. In terms of 8 hours of work per day, a single excavator can save fuel up to 47 L per day and reduce carbon dioxide emissions by 123.6 kg.

Pressure oscillation in hydrostatic drive trains can cause noise and damage to components. They impair function and reliability. The visualization of the oscillation mode helps to clarify the causal relationships in the hydrostatic drive train and is a basis for the development of remedial measures. Analysis of the pressure oscillation situation, however, can only be carried out in the complete system, since line branching and the impedance of the hydrostats have an influence on the resonance frequencies and the oscillation modes. If only the line length between the components is considered in the pressure oscillation analysis, neither the calculated frequencies nor the position of the pressure antinodes where possible remedial measures are to be placed are correct. This paper presents the metrological determination of the impedance of a hydrostat on a functional test bench (“mobile impedance measurement”) and the preparation of the measurement data for the subsequent simulative pressure oscillation analysis of a hydraulic drive train.

Virtualization of products means the representation of some of their properties by models. In a stronger digitalized world, these models will gain a much broader use than models had in engineering so far. Even for one modelling aspect different models of the same product will be used, depending on the specific need of the model user. That need may change in the course of product life, between first product concepts till over the different phases of development, to product use, maintenance, or even recycling. Since a digitalized world use of these diverse models will not be limited to experts model consistency will play a much stronger role. Model hierarchies will play a stronger role and can serve also as means for teaching product users a deeper understanding of product properties. A consistent model hierarchy leading from a simple to a more advanced property representation can support this learning process. In this paper perturbation methods are analyzed as a means for setting up model hierarchies in a consistent manner. This is studied by models for the behavior of a electrohydraulic drive, which consists of a variable speed motor, a pump, a double stroke cylinder and a counterbalance valve. Model hierarchy is achieved by model reduction in the sense of perturbation theory. The use of these different models for different questions in a system design context and their interrelations are exemplified.

This paper aims to show that controlled hydraulic drives, when properly considered and approached, are a technology that allows for a systematic and safe system design with regard to performance and energy efficiency. Controlled hydraulic drives are predestinated to be an indispensable alternative to electromechanical drives for many fields of application, especially against the background of Industry 4.0. But hydraulic drives will only be able to play this role if they see themselves as a part of mechatronics, speak the language of mechatronics and recognize the increasing importance of electric drives as part of the hydraulic toolbox as a chance.