In all common hydrostatic pumps, compressibility affects the commutation phases of the displacing chambers, as they switch their connection from/to the inlet to/from the outlet port, leading to pressure peaks, localized cavitation, additional port flow fluctuations and volumetric efficiency reduction. In common pumps, these effects are reduced by proper grooves that realizes gradual port area variation in proximity of these transition regions. This paper presents a method to automatically find the optimal designs of these grooves, taking as reference the case of external gear pumps. The proposed procedure does not assume a specific geometric morphology for the grooves, and it determines the best feasible designs through a multi-objective optimization procedure. A commercial gear pump is used to experimentally demonstrate the potentials of the proposed method, for a particular case aimed at reducing delivery flow oscillations.

This paper describes a high fidelity simulation model for GEROTOR pumps. The simulation approach is based on the coupling of different models: a geometric model used to evaluate the instantaneous volumes and flow areas inside the unit, a lumped parameter fluid dynamic model for the evaluation of the displacing action inside the unit and mechanical models for the evaluation of the internal micro-motions of the rotors axes. This paper particularly details the geometrical approach, which takes into account the actual geometry of the rotors, given as input as CAD files. This model can take into account the actual location of the points of contact between the rotors as well for the actual clearances between the rotors. The potentials of the model are shown by considering a particular GEROTOR design. A specific test set-up was developed within this research for the model validation, and comparisons in terms of steady-state pressure versus flow curves and instantaneous pressure ripples are shown for the reference pump.

The following paper presents a one-dimensional numerical model for simulating transient thermohydraulic pipe flow based on the Method of Characteristics. In addition to mass and momentum conservation, the proposed scheme also guarantees compliance with the laws of thermodynamics by solving the energy equation. The model covers transient changes in fluid properties due to pressure changes, heat transfer and dissipation. The presented methodology also allows the computation of the transient temperature distribution in the pipe wall through an additional ordinary finite difference scheme. The numerical procedure is implemented in the commercial simulation software DSHplus. The capability of the code is examined by comparing the simulation results with theoretical solutions and experimental data.

Friction force oscillations caused by changing properties of the contact zone between brake disc and pad are well known from various applications. Resulting effects like brake judder are known phenomena in brake technologies and in the scope of various scientific work. A new measure to potentially reduce brake torque oscillations is the active compensation with the use of the control system of a self-energizing hydraulic brake (SEHB). New in comparison to traditional disc brakes is the fact that the brake torque is measured by the pressure in an additional supporting cylinder. Thus, the brake system is able to work in brake torque control mode. Within this paper a dynamic simulation model of the SEHB is shown and evaluated with measurement data achieved from a full scale test rig for railway applications. Based on the simulation model a pressure control strategy is developed to minimize brake torque oscillations of lower frequencies. The control parameters of the simulation are transferred to the experimental setup. Finally, simulation and experimental results are compared. Future work will deal with the development of control strategies to additionally minimize brake torque oscillations of the higher dynamics.

The implementation of an energy recovery system for retreiving otherways wasted energy is an effective method for reducing the overall energy consumption of a mobile machine. In a fork lift, there are two subsystems that can be effectively modified for recovering energy. These are the driveline and the lift/lower function of the mast. This study focuses on the latter by studying a recovery system whose main component is a hydraulic transformer consisting of a hydraulic motor, a variable displacement pump and an induction motor. Since the flow rate/pressure - ratio can be modified, the utilization of the hydraulic transformer enables downsizing of the accumulator volume. However, the decrease of the gas volume leads to an increase in the compression ratio of the accumulator, which in terms leads to higher gas temperatures after charging and consequently to higher thermal losses during holding phase. In order to reduce these losses, a thermally regenerative unit was implemented to the gas volume of an accumulator to reduce the temperature build up during charging. In this study, the effect of improving the thermal characteristics of the accumulator to the efficiency of the whole energy recovery system is investigated by means of measurements.

Dirt ingress in hydraulic cylinders is one of the sources that leads to pollution of hydraulic systems. There are already several test rigs to investigate external contamination mechanisms. However, until now only the behavior of the whole sealing system was analyzed. A new testing method to understand the dirt particle transport between a reciprocating motioned rod and a wiper is presented. The new approach aims to avoid known issues such as limited reproducibility and long duration. The paper describes the test rig design and operating principle. First measurement results are shown.

Air contamination strongly decreases the efficiency of fluid power systems and when the allowable limits are exceeded, the performance of the system deteriorates. The hydraulic reservoir performs the function of releasing the entrained air of the hydraulic system to the surroundings. In recent years, the reservoir design has become an important task in the design of the hydraulic system due to space restrictions forcing the use of small sized reservoirs. Despite this fact, experimental results on an air release are not available. In this paper, an experimental investigation of the air release in hydraulic reservoirs is presented. A test apparatus using an optical method as well as the post-processing of the results is described. These are given in terms of an air release rate for different reservoir designs over a wide range of oil flow rates and air loads. The current study is a significant step forward in the design of fluid power systems, as it provides an experimental procedure to measure the air release in the hydraulic reservoir as well as its quantitative analysis.

The drive train components and the machine control system significantly influence the fuel consumption of mobile machinery. The demonstrator vehicle “Green Wheel Loader” developed within the joint research project “TEAM” combines the most promising drive concepts currently available for mobile machines with an innovative operating strategy. The developed drive and control system proved its functionality and performance under realistic operation conditions in a gravel pit. Reference test showed 10 – 15 % fuel savings of the prototype vehicle compared to a state-of-the-art series machine.

The focus of the present contribution is hydraulic energy recovery by means of hydropneumatic multi-chamber accumulators. A simulation study is presented comparing two different multi-chamber accumulator concepts for energy recovery in an exemplary load case involving a forklift mast. The first concept is based on the “Double Piston Accumulator” /1/. It is compared to the so-called “Digital Accumulator” /2/. Both similarities and differences of the two concepts are discussed in the presentation.

In the current study a variable speed pump controlled hydrostatic circuit where an underlapped shuttle valve is utilized to compensate the unequal flow rate of a single rod actuator is analyzed. Parameters of the shuttle valve are included in the system analysis, rather than treating it as an ideal switching element as handled in literature. A linearized model of the system is obtained. An inverse kinematic model, which calculates the required pump drive speed for a desired actuator speed and given pilot pressure input, is formed. A numerical stability analysis program is developed, and the stability of all possible shuttle valve spool positons is determined. The theoretical findings are validated by non-linear simulation model responses.