Hydraulic Actuator Research Articles

Analyzing Operational Dynamics: Centralized Load Distribution and Suspended Wagons in Self‐Propelled Trains

ABSTRACTThis paper primarily focuses on the distribution of axial loads in railway networks. The analysis assesses the advantages and disadvantages of articulated trains. In addition, the perspectives and proposed solutions of academicians are analyzed. Simpack accurately models all aspects of this articulated train model. Subsequently, the program emulates the control system of the train. This study demonstrates a control system that utilizes a hydraulic actuator. The proposed model and control system actuator's dynamic response are evaluated according to EN14363 and UIC518 standards to validate the functionality of the component. The stability of a railway train, particularly when making turns, relies on the proper allocation of weight on the wheels and axles. This research investigates the hazards associated with the uneven distribution of loads in train wagons, particularly when navigating curving tracks. A train designed for intercity travel was constructed utilizing a specific control system. The discrepancy in axle load is mitigated by implementing a straightforward control method. The train's carriage, which is suspended without bogies, resulted in fluctuating axle load. A disparity in axle load was established by an actuator positioned between the wagons. The control mechanism minimized load disparity and regulated axle load.

Simulation analysis and experimental research on static performance of water-hydraulic pressure difference control valve

Many hydraulic tools, like hydraulic cylinders and hydraulic artificial muscle joints are operated by adjusting pressure differences between different zones. Typically, the method employed to change the pressure difference is establishing hydraulic bridges and adjusting liquid resistance. While effective, this method's drawback is complex structures. To address this issue, a water-hydraulic pressure difference control valve, integrating two hydraulic bridges, was designed. The static performances including the output pressure difference, the flow rate and the force acting on the valve core were analyzed using AMESim and computational fluid dynamics simulations. Based on the simulation results, a prototype of voice coil motor direct drive pressure difference control valve was manufactured and the corresponding experiments were carried out. The computational fluid dynamics simulation results show that the internal leakage and the through-flow capacity difference between throttling grooves affect the flow field characteristics of the valve. When the pump pressure is 3 MPa and the valve opening is at the middle position, the internal leakage increases the flow rate from 2.25 L/min to 2.38 L/min, and the through-flow capacity difference reduces the control port pressure from the theoretical analysis of 1.5 MPa–1.41 MPa. Furthermore, combined with the analysis of the external liquid resistance, the AMESim model of the pressure difference control valve is modified. When the pump pressure is 3 MPa, the pressure difference and flow rate average deviations between the modified AMESim model and the experiment are 0.021 MPa and 0.048 L/min. Finally, a rotational angle experiment for a water hydraulic artificial muscle joints showed satisfactory control effects, suggesting the valve's application in controlling hydraulic tools and actuators.

Optimized design and performance testing of hydraulic electrostatic actuator

ABSTRACT Hydraulic electrostatic actuators have become a research hotspot for their inherent flexibility and safety of human-machine interaction. This paper aims to combine the characteristics of dielectric elastomers and fluid actuators, enhancing the dielectric constant and breakdown field strength by modifying Al2O3 on the surface of nanostructured BaTiO3 and in order to develop a hydraulic electrostatic actuator with silicone rubber as the matrix material. Single-factor experiments were firstly conducted to confirm the range of three factors affecting the actuation strain of the actuator: BaTiO3@Al2O3 content, thickness of the silicone rubber elastomer film, and pre-stretching ratio coefficient. The response surface methodology was used to study the interactive influence of the above three influencing factors on the actuation strain. It was obtained that A has an insignificant influence on the actuation strain, AB has a significant influence on the actuation strain, and B, C, AC, and BC have a highly influence on the actuation strain. Maximizing actuation strain as the optimization objective yielded the combination results of each factor: BaTiO3@Al2O3 content of 2.57%, thickness of 0.60 mm, and pre-stretching ratio coefficient of 2.50. Actuation strain tests were conducted with optimized parameters under no-load. The experimental results of the actuation strain test show that the relative error between the test value and the model prediction value of 16.47% is less than 5%, and the optimization model results are reliable. The optimized hydraulic electrostatic actuator was tested for actuation strain and electrical performance under different loads. The experiment showed that the maximum actuation strain of the hydraulic electrostatic actuator was 17.20% under a load of 100 g. The critical breakdown current of the actuator ranged from 115 μA to 130 μA, and the maximum electromechanical conversion efficiency of the actuator under different loads was 67.93%. Finally, a joint actuating device was developed based on the structure of the actuator, amplifying the output displacement of the actuator to 30 mm, and the linear displacement of the soft electro-fluid actuator can be converted into a 20° rotation angle through the gear steering mechanism, thus validating the effectiveness of the hydraulic electrostatic actuator.

Neural network-enhanced internal leakage analysis for efficient fault detection in heavy machinery hydraulic actuator cylinders

This work presents a method for detecting internal leakage faults in hydraulic actuator cylinders using signal analysis and a supervised artificial neural network classifier. An artificial leakage is introduced into the hydraulic cylinder actuator, and a signal-based fault detection method is employed to process and transform the signals for internal leakage detection. The analysis focuses on extracting features from the pressure signal, particularly the peaks, which include information such as location, height, and width. After the neural network has undergone the training process, it is deployed for the purpose of categorizing fault levels into three distinct categories: “a healthy system,”“a system with a low fault,” and “a system with a high fault.” The proposed technique utilizes pressure difference signals from the cylinder chambers and extracts features from the peak signals to reduce dimensionality. The extracted features are then used for supervised training of an artificial neural network using a feed-forward algorithm. The trained network is capable of predicting the leakage class of unknown datasets. This method offers advantages such as reduced computational cost through feature extraction and dimensionality reduction, and it is capable of detecting multiple leakage classes. This study introduces a notably efficient approach, predicated on artificial neural networks, for the identification of internal leakage faults in hydraulic cylinders, with specific emphasis on faults arising from component wear and seal damage. The practical value of this research lies in its potential to significantly improve the reliability and efficiency of hydraulic systems used in heavy machinery. By utilizing neural networks for internal leakage detection, this research addresses a critical issue that can lead to costly downtime and maintenance in industrial operations.

Analysis of the ecological footprint of mining machines in the phase of material extraction and processing in LCA

Sustainability in the mining industry continues to be a challenge. Although there is research in this area, there are still no solutions supporting the assessment of environmental impact in this sector. Therefore, it is important to look for and conduct various types of analyses that will be useful in this area. Therefore, the objective of the research was to analyse the ecological footprint of mining machines in the first phase of the LCA life cycle (obtaining and extracting materials). The analysis was based on the example of a hydraulic actuator, which is considered crucial to control machines in the mining industry. The ecological footprint burdens analysed included direct and indirect land take, sequestration of carbon dioxide (CO2) emissions, and the use of nuclear energy. Life cycle assessment was carried out using the OpenLCA software with the ecoinvent v3.10 database. It has been shown that the largest amount of emissions occurs during off-site treatment of nonsulphide waste, cogeneration of heat and energy (hard coal), production of ferrochrome, high carbon, 68% Cr, and heat production in an industrial furnace using hard coal. It is proposed to carry out improvement activities that will first contribute to reducing the main environmental burdens. Then, it will be possible to significantly reduce the negative environmental impact of the hydraulic actuator's extraction and processing of materials. The results from the analysis may be useful not only for products from the mining industry but also in other areas of activity using this type of machine.

A Review on Cushioning Characteristics in High-Speed Hydraulic Actuators

Abstract High speed actuators are an integral part of the fluid power driven systems and cylinder cushioning requirement in these actuators is one of the important aspects. Cushioning is imperative in any high-speed actuator as it not only increases its life but also gives operating comfort to the operator. Fluid power driven systems are very common in many defence and industrial applications due to their high force/torque and power density. This review paper brings out the available literature in the field of hydraulic cylinder cushioning. Literature, consisting mainly of journal articles, research papers and other media contents is analysed for the key parameters of research in this field. The classification of cushioning methodology by different researchers is projected. The methodologies of modelling and simulation work carried out by various authors are analysed. Thereafter the optimization studies done for the cushion piston design in various literature are discussed. Lastly, experimental validation strategies as employed in certain papers are also brought out. Experimental study, and validation of non-conventional cushioning methodology is discussed, which is not much evidenced in the literature.

Accurate Finite-Time Motion Control of Hydraulic Actuators With Event-Triggered Input

Accurate Finite-Time Motion Control of Hydraulic Actuators With Event-Triggered Input

Design and Testing of a Multi-Cylinder Piezopump for Hydraulic Actuation

Hydraulic actuation systems are widely used in industries such as aerospace, the marine industry, off-highway vehicles, and manufacturing. There has been a shift from the hydraulic distribution of power from a centralized supply to electrical power distribution, to reduce the maintenance requirements and weight and improve the efficiency. However, hydraulic actuators have many advantages, such as power density, durability, and controllability, so the ability to convert electrical to hydraulic power locally to drive an actuator is important. Traditional hydraulic pumps are inefficient and unsuitable for low-power applications, making piezopumps a promising alternative for the conversion of electrical to hydraulic power in the sub-100 W range. Currently, the use of piezopumps is limited by their maximum power (typically a few watts or less) and low flows. This paper details the design, simulation, and testing of a multi-cylinder piezopump designed to push the envelope of the power output. The simulation results demonstrate that pumps with two or three cylinders show increasing benefits in terms of hydraulic and electrical performance due to the reduced flow and current ripple compared to a single-cylinder pump. The experimental results from a two-cylinder pump confirm this, and the effect of the phase relationship between the drive signals is investigated in detail. The experimental pump has fast-acting disc-style reed non-return valves, allowing piezostack drive frequencies of up to 1.4 kHz to be used. Custom power electronics tailored to the pump are developed. These features are critical in demonstrating the potential for multi-cylinder piezopumps to play an important role as a future actuation solution.

Study and Experimental Verification on Anti-Disturbance Control Strategy for Electro-Mechanical Servo Systems

With technological advances and industrial upgrading, electro-mechanical actuators (EMAs) have gradually replaced traditional hydraulic actuation systems. During operation, force servo systems inevitably suffer from external force or position disturbances, thus affecting the output performance of the system. Therefore, it is of significant engineering application value to develop EMA anti-disturbance control strategies that exhibit strong robustness and are more easily applicable to engineering practice. In this study, an open-loop transfer function of the system with command signals and disturbance signals as inputs was established based on the nonlinear mathematical models built for the core components of EMAs. To overcome the impact of external position disturbances on the motion performance of the force servo system, a proportional integral derivative (PID) controller was introduced and a high-order transfer function associated with various parameters such as speed and acceleration was derived and obtained as feedforward compensation based on the mathematical model. By incorporating a three-loop PID controller, the impact of external disturbance forces on the motion performance of the position servo system was overcome and the tracking accuracy of the system was also improved. Finally, simulation models were built using AMESim software (AMESim 2020, LMS Imagine.Lab, Roanne, France) and a dual-channel EMA performance testing system was developed. Simulation and test results indicated that both anti-disturbance control methods exhibited strong robustness and excellent anti-disturbance performance, with the control accuracy and dynamic performance almost unaffected by disturbances. This verified the correctness of the single-channel EMA anti-disturbance control strategy and the usability of the simulation model.

Active Disturbance Rejection Control of Hydraulic Quadruped Robots Rotary Joints for Improved Impact Resistance

Hydraulic actuated quadruped robots have bright application prospects and significant research values in unmanned area investigation, disaster rescue and other scenarios, due to the advantages of high payload and high power to weight ratio. Among these fields, inevitable collision of robots may occur when contact with unknown objects, step on empty objects, or collapse, all of which have an impact on the working hydraulic system. To overcome the unknown external disturbances, this paper proposes an active disturbance rejection control (ADRC) strategy of double vane hydraulic rotary actuators for the hip joints of the quadruped robots. Considering the order of the valve-controlled actuator model, a three-stage tracking differentiator, a four-stage extended state observer, and a state error feedback controller are designed relatively, and the extended state observer is adopted to observe and compensate the uncertainty of external load torque of the system. The effectiveness of the ADRC method is verified in simulation environment and a single joint experimental platform. Moreover, the impact experiments of the limb leg unit are carried out after introducing the proposed ADRC strategy into hip joint, the limb leg unit of quadruped robots presents better impact resistance ability.

Towards a concurrency platform for scalable multi-axial real-time hybrid simulation

Multi-axial real-time hybrid simulation (maRTHS) uses multiple hydraulic actuators to apply loads and deform experimental substructures, enacting both translational and rotational motion. This allows for an increased level of realism in seismic testing. However, this also demands the implementation of multiple-input, multiple-output control strategies with complex nonlinear behaviors. To realize true real-time hybrid simulation at the necessary sub-millisecond timescales, computational platforms will need to support these complexities at scale, while still providing deadline assurance. This paper presents initial work towards supporting (and is influenced by the need for) envisioned larger-scale future experiments based on the current maRTHS benchmark: it discusses aspects of hardware, operating system kernels, runtime middleware, and scheduling theory that may be leveraged or developed to meet those goals. This work aims to create new concurrency platforms capable of managing task scheduling and adaptive event handling for computationally intensive numerical simulation and control models like those for the maRTHS benchmark problem. These should support real-time behavior at millisecond timescales, even for large complex structures with thousands of degrees of freedom. Temporal guarantees should be maintained across behavioral and computational mode changes, e.g., linear to nonlinear control. Pursuant to this goal, preliminary scalability analysis is conducted towards designing future maRTHS experiments. The results demonstrate that the increased capabilities of modern hardware architectures are able to handle larger finite element models compared to prior work, while imposing the same latency constraints. However, the results also illustrate a subtle challenge: with larger numbers of CPU cores, thread coordination incurs more overhead. These results provide insight into the computational requirements to support envisioned future experiments that will take the maRTHS benchmark problem to nine stories and beyond in scale. In particular, this paper (1) re-evaluates scalability of prior work on current platform hardware, and (2) assesses the resource demands of a basic smaller scale model from which to gauge the projected scalability of the new maRTHS benchmark as ever larger and more complex models are integrated within it.

Dynamic model of the UC San Diego NHERI six‐degree‐of‐freedom large high‐performance outdoor shake table

AbstractThe UC San Diego large high‐performance outdoor shake table (LHPOST), which was commissioned on October 1, 2004 as a shared‐use experimental facility of the National Science Foundation (NSF) Network for Earthquake Engineering Simulation (NEES) program, was upgraded from its original one degree‐of‐freedom (LHPOST) to a six‐degree‐of‐freedom configuration (LHPOST6) between October 2019 and April 2022. A mechanics‐based numerical model of the LHPOST6 able to capture the dynamics of the upgraded 6‐DOF shake table system under bare table condition is presented in this paper. The model includes: (i) a rigid body kinematic model that relates the platen motion to the motions of the components attached to the platen, (ii) a hydraulic dynamic model that calculates the hydraulic actuator forces based on all fourth‐stage servovalve spool positions, (iii) a hold‐down strut model that determines the pull‐down forces produced by the three hold‐down struts, (iv) Bouc‐Wen models utilized to represent the dissipative forces in the shake table system, and (v) a rigid body dynamic model borrowed from robotic analysis governing the translational and rotational motions of the platen subjected to the forces from the various components attached to the platen. Extensive validation against experimental data shows excellent agreement for tri‐axial and six‐axial earthquake shake table tests. This validated model can be coupled with finite element models of test specimens to study the interaction between the shake table system and the specimens, and it offers potential for enhancing motion tracking performance through off‐line controller tuning or advanced control algorithm development.

Estimation of the clutch pressure basing on reduced order model of the hydraulic actuator system

Estimation of the clutch pressure basing on reduced order model of the hydraulic actuator system

Characteristic investigation of digital control four quadrant electro-hydrostatic actuator with separated hydraulic motor.

The asymmetric electro-hydrostatic actuator (EHA) is a promising distributed hydraulic actuation solution for the more-electric aircraft (MEA). However, the flow asymmetry is a common problem causing the poor position control accuracy and dynamics of EHA. To achieve good flow control in all quadrants and save energy in the assistive quadrants, a digital control four quadrant electro-hydrostatic actuator with a separated hydraulic motor using a novel four-quadrant division principle was proposed in this article. The theoretical model of the proposed EHA has been developed in MATLAB/Simulink and validated in the experiments. The theoretical results indicated that the increased external force allows the proposed EHA to have a constantly and partly linearly and varied motion velocity of the cylinder piston in the resistive and assistive quadrants, and the latter is determined by the specific external forces of 0.5 and 2.8kN, respectively, in the extension and retraction quadrants. Compared with EHA without SHM, in the second and fourth quadrants, the energy dissipation is reduced by 104% and 36.7%, respectively, while the motion velocity of the cylinder piston is reduced by 12.9% and 25.6%, respectively. The theoretical and experimental results indicated that the proposed four quadrants division method effectively corrects the misjudgment of quadrants by using the existing four quadrants division method under the lower external force.

Simplified soil–structure interaction modeling techniques for the dynamic assessment of end shield bridges

In this paper, the dynamic behavior of four railway bridges with integrated retaining walls, considering the effect of soil–structure interaction (SSI), is investigated both numerically and experimentally. Among these bridges, two are single-span, and the remaining two are three-span. Each bridge is equipped with numerous accelerometers and is excited by a hydraulic actuator across various frequencies. Full 3D solid Finite Element (FE) models incorporating the railway bridges and surrounding soils are developed and calibrated using the Frequency Response Functions (FRFs) from each accelerometer. Furthermore, simplified 3D solid and 2D beam models are created for each railway bridge, incorporating springs and dashpots to account for the effect of surrounding soils. The values for these springs and dashpots are obtained from simple equations, except for the impact of the backfill soil in the simplified 2D beam models, which are derived from the impedance functions of the soil medium. The performance of these simplified models is then compared to the calibrated 3D models in terms of modal properties of the first bending mode and the maximum acceleration response during high-speed train passages. The results indicate that the simplified models closely align with the calibrated models in terms of modal properties and high-speed train passage response and can be used as simple and efficient alternatives for practical usage in bridge design.

Soft Fibrous Syringe Architecture for Electricity-Free and Motorless Control of Flexible Robotic Systems.

Flexible robotic systems (FRSs) and wearable user interfaces (WUIs) have been widely used in medical fields, offering lower infection risk and shorter recovery, and supporting amiable human-machine interactions (HMIs). Recently, soft electric, thermal, magnetic, and fluidic actuators with enhanced safety and compliance have innovatively boosted the use of FRSs and WUIs across many sectors. Among them, soft hydraulic actuators offer great speed, low noise, and high force density. However, they currently require bulky electric motors/pumps, pistons, valves, rigid accessories, and complex controllers, which inherently result in high cost, low adaptation, and complex setups. This paper introduces a novel soft fibrous syringe architecture (SFSA) consisting of two or more hydraulically connected soft artificial muscles that enable electricity-free actuation, motorless control, and built-in sensing ability for use in FRSs and WUIs. Its capabilities are experimentally demonstrated with various robotic applications including teleoperated flexible catheters, cable-driven continuum robotic arms, and WUIs. In addition, its sensing abilities to detect passive and active touch, surface texture, and object stiffness are also proven. These excellent results demonstrate a high feasibility of using a current-free and motor-less control approach for the FRSs and WUIs, enabling new methods of sensing and actuation across the robotic field.

Adaptive sliding-mode delay compensation for real-time hybrid simulations with multiple actuators

Real-time hybrid simulation (RTHS) is a widely applied test method in structural engineering, which is developed from pseudo-dynamic test. Much of the past work has been centered on one-dimensional RTHS using a single hydraulic actuator. When the complexity of the problem demands to increase the number of degrees of freedom to be enforced on the boundary conditions, more than one hydraulic actuator must be used. Multiple-actuator or multi-axial RTHS (maRTHS) requires that more than one hydraulic actuator exerts the required motion on experimental substructures demanding the implementation of multiple-input multiple-output (MIMO) control strategies. A new maRTHS benchmark control problem has been developed, focusing on a frame subjected to seismic load at the base, substantially transforming and intensifying the complexity of the problem. The time delay generated by the dynamic characteristics of the loading system and the transmission process as well as the high coupling between the hydraulic actuators and the nonlinear kinematics escalates the complexity of the actuator control tracking. A sliding mode adaptive delay compensation method suitable for maRTHS is proposed, which utilizes a MIMO sliding mode method to reduce the coupling effects of actuators and the adaptive compensation method to compensate the residual delay. The effectiveness of the method is verified by numerical simulating different working conditions in the Benchmark Problem Platform.

A low-complexity fixed-time prescribed performance control for uncertain full-vehicle active suspensions with hydraulic actuators

This paper addresses the low-complexity fixed-time prescribed performance control problem for uncertain full-vehicle active suspension systems. Different from existing results that ignore the dynamics of the actuator, this paper considers a hydraulic actuator in the controller design. To address the nonlinearities of hydraulic active suspension systems, a new low-complexity fixed-time prescribed performance control method is proposed. In this method, the function approximators (e.g. neural networks (NNs) and fuzzy systems (FSs)) are not needed, which means that the heavy computational costs are avoided. Furthermore, by developing a fixed-time performance function, the proposed method can ensure that the suspension motions converge to the prescribed range within a finite time. Based on the Lyapunov theorem and Extreme Value Theorem, the stability of the closed-loop suspension system is strictly proved. Finally, the comparative simulation results show that the proposed method effectively improves the attitude stability and ride comfort of the suspension system.

Development of a pressure-, velocity-, and acceleration-dependent phenomenological friction model using experimental data of sliding tests between 11 polymers and stainless steel

This paper experimentally investigates the frictional behavior between stainless steel and 11 polymers. Particularly, the dependence of the friction coefficient on the sliding velocity, pressure, and acceleration is quantified. The novelty of this work lies in quantifying the acceleration-dependent nature of friction, correlating it to the well-documented Stick-Slip effect. The experimental setup consisted of two parallel stiff steel beams, one above the other, with a separation of 95 mm, and steel surfaces welded at the inner sides for sliding the polymers. Cylindrical polymer pads were placed between the stainless-steel surfaces and connected to a dynamic actuator to apply the displacement protocol. The protocol consisted of consecutive nominally constant-velocity ramp cycles covering velocities from 1 mm/s to 300 mm/s (with 20 mm/s increments). An additional vertical force was applied with a hydraulic actuator to reach nominal pressures in the polymers between 5 and 80 MPa. The results showed that the friction coefficient depends on the velocity, pressure, and acceleration of the motion, and a phenomenological model on these three variables is proposed. The velocity dependence can be represented through a logarithmic relationship, while the pressure dependence is through an exponential decay relationship. The acceleration dependence was represented through a linear relationship, which could capture the stick-slip effect. Overall, this work contributes to a better understanding of friction for seismic isolation systems. Since friction is the main source of energy dissipation in such structures, the proposed model will allow a higher accuracy in predicting variables of interest during the dynamic analyses of seismically isolated structures with frictional systems.

Adaptive sliding mode control with disturbance estimation for hydraulic actuator systems and application to rock drilling jumbo

For achieving high-performance control of hydraulic actuator systems, an adaptive sliding mode control with disturbance estimation algorithm is proposed and successfully applied to the hydraulic actuator systems of rock drilling jumbo. A switching extended state observer for hydraulic actuator systems is proposed, which combines the advantages of the linear extended state observer and the nonlinear extended state observer to estimate system disturbances more efficiently. The designed parameter adaptive law provides adaptivity to the system parameters, while the disturbance estimation algorithm can online estimate the unknown disturbances, such integration can enhance the adaptability and robustness of the sliding mode control algorithm. Rigorous simulation tests and practical application experiments are conducted to evaluate the performance of the proposed controller. The reliability of the designed parameter adaptive law and switching extended state observer is validated in detail in simulation studies. In the application experiments of rock drill jumbo, the results indicate the proposed controller is superior to sliding mode control with disturbance estimation and PID control. The average error of the developed controller is reduced by 58 %, 54 %, and 56 % compared to the sliding mode control with disturbance estimation controller, and 82 %, 78 %, and 79 % compared to the PID controller in tracking the low-frequency, high-frequency, and superimposed sinusoidal signals, respectively. Moreover, both the convergence of the uncertain parameters and the estimation of the unknown disturbances in the experiments are satisfactory. These experimental results adequately demonstrate the practical application value of the proposed controller.