There is a need for low-cost switching and proportional electro-hydraulic valves with low contamination sensitivity and good reliability. In an attempt to meet this need, a novel electro-hydraulic floating double-disc valve has been developed to the stage where it can be used to control hydraulic cylinders or motors directly. As the valve is significantly underlapped, problems still remain in achieving adequate hydraulic stiffness in the proportional mode of operation. The valve operation, which relies on the complex interaction between fluid and electro-magnetic forces acting on the valve discs, is described and a theoretical model of the fluid and electro-magnetic characteristics of the valve is presented. The theory shows satisfactory agreement with experimental data. A pre-production version of the double-disc valve has been designed and manufactured and it incorporates ideas for manufacturing cost reduction while at the same time conforming to CETOP 3 international valve port standards. This valve has been successfully tested as a switching or proportional device when controlling two different cylinders. Proportional control of the valve is achieved using Pulse-Width-Modulation technique. British Technology Group and University of Surrey have applied for a patent on the valve. The patented floating-disc valve has the following features: (a) 3 way or 4 way 2-position or proportional action with minor changes to produce the two types of action, (b) cartridge construction with interchangeable components, (c) low contamination sensitivity, (d) few critical dimensions, (e) no sliding surfaces, (f) CETOP valve port configuration and (g) potentially capable of operating with corrosive or non-lubricating fluids.

Recent developments of electro-hydraulic disc valves at Surrey University have shown that with a careful balance between the hydraulic and magnetic forces, this type of valve can be used as a digital or proportional device. As the valve is simpler in construction and involves very few critical dimension compared with a servo-valve, the sensitivity to contamination is considerably reduced. The dynamic response of the valve is fast due to utilising high electro-magnetic and fluid forces for actuation. The research described in this thesis is an extension of earlier work by Yuksel and Usman to improve electro-hydraulic disc valves by applying closed-loop position or pressure control to the disc. From an investigation of an unbalanced single disc valve, it was found that using position feedback can help to stabilise the disc under varying load conditions. A special differential capacitive transducer to measure the disc position was designed and constructed and was found to perform satisfactorily. As the pressure-flow characteristic of the valve can be varied by controlling the disc position, the function of the valve is similar to an electrically controlled variable orifice. Various modular configurations are proposed to perform more complicated control functions. In the final part of the research, a double disc valve is described for used in an application study to control the damping characteristic of a modified vehicle shock absorber. Initially, the valve was designed for closed-loop position control due to the non-linear hydraulic and magnetic forces. Results show that the valve can be controlled to generate the required range of damping force and has adequate dynamic performance with a response time in the range of 10 to 30 msec. However, tests using direct pressure control were also carried out. Preliminary results indicate that pressure feedback is preferable to position feedback and that by using lead compensation together with a proportional plus integral controller, stable operation is possible.

A digital position servo controller for the Electro-hydraulic system is proposed based on robust integral structure control (RISC) scheme. The main aims of the proposed system are to enhance the performance while driving the servo machine rod to track a sine-wave or step command. According to the state feed-back theorems, a simplified plant model of the Electro-hydraulic is conducted. Close-loop characteristic function of the control system will be assigned on the stable plane to ensure the state variables so that it can rapidly converge to stable point. The design steps and theoretical analysis will be described in detail. Both simulation and experimental results are shown for proving the performance.

Abstract Traditional synchronous motion control of a multi-cylinder system was always achieved by using hydraulic loops design and constrained linkage mechanisms. Therefore, these control methodologies always have many disadvantages, such as inaccuracy, cost expensive, and huge volume of the equipment, and so on. In this paper, the nonlinear control strategy was proposed to control the proportional directional valves of two-cylinder electro-hydraulic system in order to achieve synchronous motion under the consideration of unbalanced and uncertainty loading. Besides, in order to explore influence of different loading to the system, two-cylinder mechanism was designed to have individual loading device without any hardware constrain between two pistons. And the maximum loading capacity for one piston is 210kg. Due to the highly complicated coupling effect of internal pressure and flow rate for two cylinders, in this paper, feedforward controller with three fuzzy controllers was designated to overcome the problem of synchronous motion. In the first, the feedforward controller of each cylinder is developed to track a desire velocity trajectory. Then, the fuzzy control of each cylinder was specified to improve the individual tracking performance. Finally, the third fuzzy controller was performed to compensate the coupling effect of two-cylinder in order to progressively improve the performance of synchronous motion. According to the experimental results, the proposed control strategy for synchronous motion of two-cylinder system was verified and the maximum synchronous error of the total system was controlled to be within 10mm. Keyword: synchronous motion; proportional directional valve; fuzzy controller; feedforward controller

Along with increased oil prices and rising environmental issues, a demand for alternatives to combustion engine driven hydraulic applications has risen. In the field of mobile hydraulics, the hydraulic applications have traditionally been driven by the combustion engine of the vehicle on which they are mounted. By instead using a battery driven power pack the hydraulic application is able to operate without the engine running, saving fuel costs and reducing sound levels. In this thesis, the concept of using an electric-hydraulic power pack with a variable-speed electric motor and a fixed-displacement hydraulic pump to provide power to a truck-mounted loader crane is investigated. This concept is compared to an electric-hydraulic system imitating the conventional combustion engine system by using a fixed-speed electric motor connected to a variable-displacement pump. The use of a variable speed motor where the speed can be controlled electrically by a control unit creates possibilities of using different control strategies to improve the efficiency and responsiveness of the application. The efficiencies of the two electric-hydraulic systems are compared by constructing a physical test rig and performing measurements in a test lab. The tests have shown an increased efficiency of about 20 \% when using the variable speed configuration. Three different control strategies are also investigated and tested on a simulated model. The simulations show that very good responsiveness and robustness can be achieved by using a hydraulic flow feed forward controller with a complementary pressure feedback controller. Furthermore, by controlling the hydraulic flow to the heaviest of the crane loads entirely with the flow from the hydraulic pump, the hydraulic pressure can be reduced and energy efficiency increased.

Semi-active dampers utilizing various working principles have been developed for a variety of vehicles. These semi-active dampers have been designed to resolve the ride and handling compromise associated with conventional passive dampers, and increase vehicle stability. This thesis briefly reviews existing semi-active damper designs, including but not limited to MR dampers, before presenting two new prototype semi-active hydraulic dampers. Both prototype dampers are designed to provide a large force range while maintaining easily controllable valve characteristics. The first of these dampers served primarily as a proof of concept and a means of understanding the dynamics of a disc valve housed inside the main piston. The valve design is presented, along with other information concerning the fabrication of the Initial Prototype damper. Test results are presented and analyzed, and a second iteration of the valve is designed. The Final Prototype damper is a scaled up version of the initial design, with refinements made in piston geometry, internal disc profile, and dynamic seals. This large force range damper is tested and results are compared with existing MR dampers. The Final Prototype damper provides a significantly larger force range when compared with typical MR dampers. Finally, to conclude this research, the vehicle dynamics implications of the Final Prototype damper are discussed and recommendations for further study are made. / Master of Science

Besides the braking system the steering system is one of the most important systems on vehicles. The reliability and the performance of a steering system decides on the controllability of the vehicle under normal conditions as well as emergency situations. In everyday use the characteristics, the connectivity to assistance systems and the energy efficiency of the steering system become more and more important to fulfill the increasing demands regarding fuel consumption, carbon dioxide emissions and comfort. To meet these demands, new steering systems must be implemented and new technologies have to be developed. This contribution compares different approaches regarding functionality and energy efficiency to give an indication which system is the most promising solution for future front axle steering systems as well as rear steered axles (tag- or pusher axle) on trucks.

This paper focuses on thermal analysis of a direct driven hydraulic setup (DDH). DDH combines the benefits of electric with hydraulic technology in compact package with high power density, high performance and good controllability. DDH enables for reduction of parasitic losses for better fuel efficiency and lower operating costs. This one-piece housing design delivers system simplicity and lowers both installation and maintenance costs. Advantages of the presented architecture are the reduced hydraulic tubing and the amount of potential leakage points. The prediction of the thermal behavior and its management represents an open challenge for the system as temperature is a determinant parameter in terms of performance, lifespan and safety. Therefore, the electro-hydraulic model of a DDH involving a variable motor speed, fixed-displacement internal gear pump/motors was developed at system level for thermal analysis. In addition, a generic model was proposed for the electric machine, energy losses dependent on velocity, torque and temperature was validated by measurements under various operative conditions. Results of model investigation predict ricing of temperature during lifting cycle, and flattened during lowering in pimp/motor. Conclusions are drawn concerning the DDH thermal behavior.

The theoretical stability analysis of mold level control system for slab continuous casting machine is presented in this thesis. In the procedure of analyzing the stability of the mold level control system, the PLC program written for the control system is studied first in order to obtain the mathematical model of a PID controller. Then the mathematical models of servo-amplifier, servo-valve, electro hydraulic system to the output of mold level are established. A simulative control system using Matlab software is constructed in accordance with these mathematical models so that not only the results of stability analysis can be verified but also the dynamic response of controlled system can be studied. Finally, the effects of some potential disturbance on system¡¦s dynamics, stability, and control accuracy are also analyzed.

<p dir="ltr">In recent years increasingly stringent regulations regarding the pollution emissions and greenhouse gasses (GHG) of off-highway vehicles have emerged. However, recent studies underscores that off-highway vehicles have an average efficiency of 30%. In response, researchers are exploring the possibility of electrifying these vehicles with electric machines (EMs) potentially undertaking one, multiple, or all the vehicular functions previously reliant on internal combustion engines (ICEs).</p><p dir="ltr">Contemporary off-highway vehicle technology revolves around hydraulic systems tailored for diesel engines, tuned to specific torque characteristics and operating at a single speed. While replacing the prime mover with electric machines, the proper hydraulic supply capable of matching the same torque speed characteristics must be found. Furthermore, it must be determined whether an integration capable of reducing the mass, cost, and volume can be implemented, and if energy recuperation is possible. </p><p dir="ltr">In essence, achieving the desired transformation in off-highway vehicle technology necessitates a comprehensive reevaluation of both hydraulic systems and power sources, with electrification emerging as a promising strategy for harmonizing efficiency, emission standards, and performance expectations. </p><p><br></p><p dir="ltr">This work proposes guidelines to systematically design EMs and positive displacement hydraulic gear machines (HMs), along with their integration in an electro-hydraulic unit (EHU). To do so, three different variants of EHU are produced. The first variant features an external gear machine (EGM) integrated in a permanent magnet synchronous electric machine (PMSEM). The second and third variants integrate an internal gear machine (IGM) and a PMSEM, wherein the final variant introduces features endowing its operation at high rotational velocities.</p><p dir="ltr">The EM and HM constituting all variants of EHU are designed using a genetic algorithm-based optimization framework. This optimization framework encapsulates dedicated models for the EM and the HM that allow the calculation of the EHU performance. The first optimization objectives are the minimization of power consumption over the duty cycle of the selected reference machine, the minimization of the pressure and flow ripple, and maximization of the power density of the EHU. The optimization of the second and third variants instead only aims to maximize the total efficiency and power density of the EHU. </p><p dir="ltr">After having determined the parameters of the EHU through the optimization procedure the designs are refined with thorough simulations focusing on the fluid-dynamic features and the design of the axial balance system of the HMs. </p><p dir="ltr">The three variants present an increasing level of HM and EM integration and component reduction. While in the first variant HM and EM have a dedicated housing, and the HM is only positioned in the inert region of the EM, in the latest variants the HM and the EM also share the same casing. The first variant of EHU is air cooled by a radial fan system attached to the EM rotor and openings machined in the casing. The second variant takes advantage of the extreme integration and the differential pressure generated across the HM to liquid cooling the EM. The third variant necessitates the use of an external system to cool the EM. </p><p dir="ltr">To prove the effectiveness of the design process the first two EHU variants are prototyped and tested. The first EHU variant is tested both in a standalone configuration and on the reference machine showing total efficiency values up to 69%, proving its functionality and proving the capability of recuperating energy. The tests conducted on the second variant EHU show a volumetric efficiency that ranges between 81% and above 96% for a pinion rotation velocity of 6000 rpm proving the value of the presented design process. Despite the good quality of the volumetric efficiency values, this EHU variant present morphological limitations that negatively impact its mechanical efficiency. Finally, the third EHU concept is presented not only to remedy the morphological limitations of the second variant but also to address the challenges raised by high rotational velocity operation. </p>