Rotational hydraulic actuators, e.g. motors, provide infinite stroke as there is no conceptual limit to how far they can turn. By contrast linear hydraulic actuators like cylinders provide only limited stroke by concept. In the world of electrical drives, linear motors provide infinite stroke also for linear motion. In hydraulics, the presented Hydraulic Infinite Linear Actuator is a novelty. This paper presents the novel Hydraulic Infinite Linear Actuator (HILA). The contribution is an assessment of properties relevant for control like high hydraulic stiffness and is based on analysis, simulation and measurements.

An efficient system development needs reuse, traceability and understanding. Today, specifications are usually written in text documents. Reuse means a copy and paste of suitable specifications. Traceability is the textual note that references to affected requirements. Achieving a full context understanding requires reading hundreds of pages in a variety of documents. Changing one textual requirement in complex systems can be very time-consuming. Model-based systems engineering (MBSE) addresses these issues. There, an integrated system model is used for the design, analysis, communication and system specification and shall contribute to handling the system complexity. This paper shows aspects of this approach in the development of a wheel loader\'s attachment system. Customer requirements will be used to derive a specification model. Based on this, the author introduces the system and software architecture. The connection between requirement and architecture leads to a traceable system design and produces the huge advantage of MBSE.

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.

Complexity management is the key to success for mobile machinery where the variety of customers and applications requires individual solutions. This paper presents the way Bosch Rexroth supports each OEM with hydraulic controls – from specification and conception towards application and production. It gives examples how platforms and processes are optimized according to the customer needs. The demand for flexible, short-term deliveries is met by an agile production with the technologies of Industry 4.0.

Hydraulic main stages for off highway machines have usually electromagnetic driven pilot valves. You rarely find stepper motor driven pilot systems that are directly positioning the main spool in the sectional control valve. The presented concept shows the development of an actuator in a unique setup to fulfill the requirements of most off- highway applications. Precise positioning, strength, speed and fail safe requirements were the main goals of the concept. The concept has a two phase BLDC transversal flux motor with a single gear stage transmission. The software and control unit are specially designed for this electric motor setup. On a test bench some results of the first samples reveal the technical potential of this concept. The development of the actuator was done in-house of Thomas Magnete GmbH (mechanical, electronical, and software development).

Most commercially available valves are able to produce a large flow rate or a fast response, but are incapable of producing both simultaneously. Commercially available valves that can achieve both are expensive as they require multiple stages of actuation and piloting pressures to deliver large flow rates quickly, preventing them from being broadly used in fluid power applications. This work investigates the design of an Energy Coupling Actuated Valve (ECAV) that is capable of solving this trade-off between large flow and fast switching times through the use of an innovative, high performance actuation system. The ECAV is a new development in valve technology in the area of hydraulic, high speed, proportional and digital on/off valves. High speed actuation is produced through the intermittent coupling of a kinetic energy source with a translational poppet or spool. This coupling process occurs through the use of magnetorheological fluid and a controlled magnetic flux through the fluid in the energy coupler. The ECAV has several design advantages including proportional force control and a large (7mm) stroke capability. Early results predict a nominal flow rate of 100 L/min at a 5 bar pressure drop can be achieved with a 3 ms on/off response time.

Noise emission is a major drawback of the positive displacement machine. The noise source can be divided into structure borne noise source (SBNS) and fluid borne noise source (FBNS). Passive techniques such as valve plate optimization have been used for noise reduction of axial piston machines. However, passive techniques are only effective for limited operating conditions or at least need compromises in design. In this paper, active vibration control of swash plate is investigated for vibration and noise reduction over a wide range of operating conditions as an additional method to passive noise reduction techniques. A 75cc pump has been modified for implementation of active vibration control using the swash plate. One tri-axial acceleration sensor and one angle sensor are installed on the swash plate and a high speed servovalve is used for the swash plate actuation. The multi-frequency two-weight least mean square (LMS) filter synthesizes the servovalve input signal to generate a destructive interference force which minimizes the swash plate vibration. An experimental test setup has been realized using Labview field-programmable gate array (FPGA) via cRIO. Simulation and experimental studies are conducted to investigate the possibility of active vibration control.

For decades, duplex filters have been put to use virtually unmodified. Technologies, handling and use of materials show enormous potential for improvement. Filter element emoval/replacement is performed according to a complex process sequence. With the newly developed Duplex Filter, the market demands concerning simple filter element removal/replacement, as well as weight and pressure loss reduction are fully met.

The contribution compares results of Large Eddy Simulations of the cavitating flow in a model oil hydraulic spool valve using an Euler-Euler and a one-way coupled Euler- Lagrange model. The impact of the choice of the empirical constants in the Kunz cavitation model is demonstrated. Provided these are chosen appropriately the approach can yield reasonable agreement with the corresponding experiment. The one-way Euler-Lagrange model yields less agreement. It is demonstrated that this is due to the lack of realistic volumetric coupling, rarely accounted for in this type of method. First results of such an algorithm are presented featuring substantially more realism.

In this paper, we present a new compact hydraulic linear actuator. The concept is developed to change the rolling piston diameter of an active air spring during usage. By doing so, the air spring can actively apply pressure and tension forces. The actuator is designed for small movements at high forces. It is insensitive to side forces, which are introduced by the bellows rolling on the rolling piston of the air spring. A diaphragm sealing is used to minimize friction. Hence a precise adjustment of small displacements at high dynamics is possible and the system is completely leakage-free. We describe the design and development of this actuator and show first measurement results from preliminary tests to show its functionality.