Improved modelling and driving of hydraulic asymmetric cylinders systems

Abstract

Asymmetric and symmetric cylinder drives are the major actuators for hydraulic linear motion control applications. The asymmetric type is the most popular one and can be found in various areas, industrial, civil and even aerospace. Its compact design in structure and high power to weight ratio are highlighted, but nonlinear behaviours are found in these applications. An asymmetric cylinder is usually controlled by a symmetric ported control valve, which introduces difficulty in the motion control of the cylinder. To avoid such issue, symmetric cylinder drives are typically chosen for high-performance dynamic response applications. This thesis focusses at improving the modelling and driving of the asymmetric cylinder drive system.The major nonlinearities in asymmetric cylinder systems occur when the control valve crosses its null position, causing pressure jumps, and system parameters switching to new values. In this scenario, the system is usually operating at low speed, in which the friction influence is an important factor. In addition, energy efficiency is always a concern in hydraulic applications, a valve-controlled asymmetric cylinder drive can have better controllability than a pump-controlled system, but its energy efficiency is worse than the latter. The aims of this research are to:• Improve modelling of asymmetric cylinder drive systems.• Improve the driving of asymmetric cylinder systems at low speed and velocity reversal with friction consideration.• Combine the advantages of a valve-controlled and a pump-controlled asymmetric cylinder drive system for energy efficiency purpose.A detailed analysis of a valve-controlled asymmetric cylinder system is carried out, and the nonlinearities behaviours are investigated in structure and theory aspects. The simulation modelling in this thesis reveals the system performances when the control valve travels across its null position, and this process is simulated with a numerical solution. An analytical solution is developed, showing that the new analytical solution runs 200 times faster than the original numerical method in simulation. Friction is inevitable in any device and it plays an important role in hydraulic nonlinearities, especially when the system runs at low speed and velocity reversal. Existing friction models are investigated and reviewed, but limited friction models considered the pressure influence in hydraulics. A new friction model for hydraulic system is developed on current LuGre model. This new friction model includes pressure term, acceleration term and velocity term. The new friction model is validated by experimental results and improvements are demonstrated.Under the consideration of energy efficiency, functionality, cost and feasibilities, a hybrid pump-controlled asymmetric cylinder system that combines the merits of a valve-controlled system and a pump-controlled system is implemented. Its pros and cons are investigated and analysed. Its simulation model is built to aid further analysis of the existing nonlinearities.Comparing the simulation results of the hybrid pump-controlled asymmetric cylinder system with the valve-controlled asymmetric cylinder system, the energy efficiency of the hybrid pump-controlled system is 20% better and can be further optimised. The various experimental results validate the simulation model of the hybrid system. Therefore, the functionality and feasibility of the energy efficient design of the hybrid pump-controlled system are validated.The design circuit of the hybrid pump-controlled asymmetric cylinder system is not fully optimised, and improvements can be achieved in future works including replacing the pilot shifted four-way valve with a solenoid valve, adding accumulators to stabilise the pressure in the service line and adding a controller to optimise the system performance.