Independent metering poses a possibility to improve energy efficiency of throttlecontrolled hydraulic single-rod cylinder drives. This paper deals with energetic potentials gained through variable circuitry that come along with independent metering. A method to assess energetic potentials is described, based on load specific, optimal operating modes. As a means of yielding maximum energy efficiency for a wide range of applications, a smooth mode switching algorithm that minimizes losses and allows good motion tracking is proposed. The mode switching algorithm is validated in simulation and on a test stand.

Measures of individualization and integration offer a great potential for further development and optimization in hydraulic drive technology. Advantages are seen especially for energy efficiency and functionality. These potentials motivate current research activities for displacement controlled systems and for valve controlled structures. For the latter, the focus lies on strategies of independent metering. Furthermore, expected challenges for the future are discussed.

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. 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 The fixed relation 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. The flow directions are fixed for a given spool position; therefore, no energy recuperation and/or regeneration ability is available. 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. 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. 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: Mode switches The mode switches are accomplished without knowledge about the pressures in the system Throttle losses With the new system approach, choice of control and measure signals, the throttle losses at the control valves are reduced Smooth mode switches The system will switch to regenerative mode automatically in a smooth manner when possible Use energy stored in the loads The load, e.g. a cylinder, is able to be used as a motor when possible, enabling the system to recuperate overrun loads 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.

This contribution presents an operating strategy for a novel valve structure for mobile machines’ working hydraulics which combines the flexibility and energetic benefits of individual metering with the functionality of common primary pressure compensation (IPC). The aim is to set up a system that uses a minimal amount of sensors and simple control algorithms. A control strategy theoretically described in /1/ is modified to facilitate the practical implementation on a mini excavator implement as a test rig. This test rig consists only of components that are currently available off-the-shelf to show that it is possible to develop an individual metering system under these economic restrictions. The novel is more energy efficient than common flow sharing systems but provides the same functionality. The control algorithm is experimentally evaluated in terms of functionality and energy consumption. Simulations show potential for further improvements.

As intelligent hydraulic systems with embedded sensors become more ubiquitous, the real or perceived reliability challenge associated with sensors must be addressed to encourage their adoption. In this paper, a fault-tolerant control strategy for an intelligent independent metering valve that allows continued operation if a sensor fails is described. The twin-spool valve example utilizes position sensors to stabilize the spool positions and eliminate hysteresis, and pressure sensors to provide digital pressure compensation, electronic load sensing, and other features. An independent metering valve has redundancy provided by four sensors working together to control the flow into and out of a single actuator. Although two sensors are needed to control the flow through a spool, the controller can be reconfigured to ensure the flow is always controlled on the spool with both sensors working. To accomplish this, the concept of cross-port pressure control is introduced that uses the faulty side of the valve to maintain constant pressure on the non-faulty side. By maintaining a constant pressure, the flow in and out of the actuator are balanced. Experimental results on the boom of a backhoe demonstrate the operation of the fault tolerant control strategy.

<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>

Independent metering poses a possibility to improve energy efficiency of throttlecontrolled hydraulic single-rod cylinder drives. This paper deals with energetic potentials gained through variable circuitry that come along with independent metering. A method to assess energetic potentials is described, based on load specific, optimal operating modes. As a means of yielding maximum energy efficiency for a wide range of applications, a smooth mode switching algorithm that minimizes losses and allows good motion tracking is proposed. The mode switching algorithm is validated in simulation and on a test stand.

This contribution presents an operating strategy for a novel valve structure for mobile machines’ working hydraulics which combines the flexibility and energetic benefits of individual metering with the functionality of common primary pressure compensation (IPC). The aim is to set up a system that uses a minimal amount of sensors and simple control algorithms. A control strategy theoretically described in /1/ is modified to facilitate the practical implementation on a mini excavator implement as a test rig. This test rig consists only of components that are currently available off-the-shelf to show that it is possible to develop an individual metering system under these economic restrictions. The novel is more energy efficient than common flow sharing systems but provides the same functionality. The control algorithm is experimentally evaluated in terms of functionality and energy consumption. Simulations show potential for further improvements.

Measures of individualization and integration offer a great potential for further development and optimization in hydraulic drive technology. Advantages are seen especially for energy efficiency and functionality. These potentials motivate current research activities for displacement controlled systems and for valve controlled structures. For the latter, the focus lies on strategies of independent metering. Furthermore, expected challenges for the future are discussed.

As intelligent hydraulic systems with embedded sensors become more ubiquitous, the real or perceived reliability challenge associated with sensors must be addressed to encourage their adoption. In this paper, a fault-tolerant control strategy for an intelligent independent metering valve that allows continued operation if a sensor fails is described. The twin-spool valve example utilizes position sensors to stabilize the spool positions and eliminate hysteresis, and pressure sensors to provide digital pressure compensation, electronic load sensing, and other features. An independent metering valve has redundancy provided by four sensors working together to control the flow into and out of a single actuator. Although two sensors are needed to control the flow through a spool, the controller can be reconfigured to ensure the flow is always controlled on the spool with both sensors working. To accomplish this, the concept of cross-port pressure control is introduced that uses the faulty side of the valve to maintain constant pressure on the non-faulty side. By maintaining a constant pressure, the flow in and out of the actuator are balanced. Experimental results on the boom of a backhoe demonstrate the operation of the fault tolerant control strategy.