Hydraulic Control Valve Research Articles

Hydraulic control valve integrated novel semi active roll resistant interconnected suspension with vertical and roll coordinated control scheme

Though the interconnected active suspension enhances the performances of roll dynamics along with the primary functions of passive suspension, it requires an external pressurized fluid supply. Also, higher energy is required to attain the variable damping force in an active interconnected system. Therefore, this research attempts to control the vehicle roll without an external fluid supply by novel semi-active based roll-resistant interconnected suspension system (SARR-HIS). The variable damping is achieved by utilizing the pressure developed in the chambers and hydraulic control valve (HCV), while the suspension compresses. The amount of the flow passes through the HCV is controlled by a model predictive controller. In addition, GA based optimization were performed to identify the optimal passive roll-resistant hydraulic interconnected suspension (PRR-HIS) parameters. For the controller design, vehicle plant model is estimated by the simple identification method in Matlab environment. On the AMESim platform, vehicle with SARR-HIS system integrated model was built and controlled in a co-simulation environment. To assess the effectiveness of the proposed suspension and its control strategy, the anti-roll bar (ARB) integrated passive standalone suspension, optimized PRR-HIS, and proposed SARR-HIS systems are tested under C class road roughness without steer and double lane change maneuver.

Modern Techniques for Remanufacturing Hydraulic Equipment in the Context of Circular Economy and Energy Efficiency

The article presents several current methods of remanufacturing hydraulic components, a trend that is encouraged, on the one hand, by concerns about reducing material consumption in the context of the circular economy - some of these materials being expensive or in short supply. On the other hand, remanufacturing by modern methods can lead to a decrease in energy consumption in the devices concerned, due to obtaining shapes that are difficult to achieve by classical procedures. Among the remanufacturing processes considered there are additive manufacturing, metal coating, reverse engineering, etc. An important step in the remanufacturing process is testing of components, which certifies the achievement of performances at least equivalent to those of the original products. To this end, the article presents a test bench solution with the help of which tests can be carried out on hydraulic devices such as hydraulic pumps and (linear or rotary) motors, hydraulic directional control valves or other types of valves.

ПРИМЕНЕНИЕ ЭЛЕКТРОТЕХНОЛОГИЙ ДЛЯ ВОССТАНОВЛЕНИЯ ДЕТАЛЕЙ СЕЛЬСКОХОЗЯЙСТВЕННОЙ ТЕХНИКИ

The technology of non-galvanized ironing of parts in the electrolyte flow with simultaneous hydromechanical activation of the plated surface is proposed, its advantages over the traditional type of coating are shown. The technological process of coating hydraulic control valve spools has been developed. The technological process of restoring spools consists of the following operations: preliminary surface preparation (mechanical treatment), degreasing, washing, anodic treatment, electrodeposition and final mechanical treatment. The designs of the installation and the electrochemical cell for ironing hydraulic control valve spools, providing optimal hydrodynamic conditions when applying coatings on worn surfaces, are proposed. Optimal modes and composition of ironing electrolyte have been defined, providing a high rate of precipitation growth (1.5...3 mm/h), adhesion strength and wear resistance of coatings. Bench and field tests of hydraulic valves with restored spools were performed, which confirmed the results of laboratory studies and the high efficiency of the proposed technology.

Energy harvesting approach to utilize the dissipated energy during hydraulic active suspension operation with comfort oriented control scheme

Even though the active suspension provides enhancement in comfort and road-holding in addition to vehicle safety and handling, energy demand is one of the major problem in commercialization. Therefore, energy harvesting from the vehicle active suspension brings greater significance to the energy management and vehicle dynamics research. The consumption of more power occurs by hydraulic active suspension for the process of fluid actuation into chamber through the control valves and instantaneously significant amount of power is being dissipated by another chamber of the same actuator. Hence, this study propose a novel approach to harvest energy from the dissipating energy of active suspension through the control valve. In order to ensure the comfort and road-holding, model predictive control effort was provided to the hydraulic control valve. Dissipated fluid during the operation was directed to the hydraulic motor to generate the power and the influence of hydraulic power generation unit is being compensated by two new approaches. For the numerical simulation, active suspension integrated four wheel vehicle model was developed in AMESim and its control valve is controlled in Matlab co-simulation environment. The 1D mapped variable and constant resistance energy harvesting schemes provided the maximum RMS power of 1385.4 W & 1427.6 W in the D-class road at 28 m/s velocity. Also, the results of both proposed energy harvesting approaches showed that the comfort oriented characteristics of active suspension such as actuator effort, comfort and road-holding were not affected.

Hydraulic control valve spool restoration by composite galvanic coating

Methods of restoration of hydraulic control valve spools by galvanic coatings are considered. Methods for preparing parts for applying electroplated composite coatings in order to increase the adhesion strength of electrolytic iron to alloy steel are proposed. The optimal modes of electrolysis for obtaining high-quality galvanic coatings are selected, the composition of the electrolyte is substantiated and the optimal content of the dispersed phase in it is selected. The design features of the coating bath for active mixing of the dispersed phase in the electrolyte are substantiated. The parameters of the technological process for spools restoration by applying composite galvanic iron-based coatings are proposed.

Дослідження стійкості роботи гідроприводу, чутливого до навантаження, на базі мультирежимного гідророзподільника

The article describes a new scheme of a hydraulic drive, which, thanks to the original design of a multimode directional control valve, has energy-efficient properties that are characteristic of load-sensing hydraulic drives. The proposed design of the multimode directional control valve ensures the operation of the hydraulic drive in four modes – unloading the hydraulic pump, regulating the flow of the hydraulic motor, the maximum flow of the hydraulic motor and protection against overload. In each of these modes, the hydraulic drive operates with low power losses due to the presence of a constant balancing pressure drop. This value is formed by a combination of design parameters of the directional control valve. The proposed value of the value of the balancing pressure drop of 0,7-0,8 MPa provides high energy efficiency of the hydraulic drive in the most critical operating mode – regulation of the hydraulic motor flow. In order to ensure the stability of the energy-efficient operation of the hydraulic drive in this mode, a research was made of the stability of transient processes with various combinations of design parameters of the overflow valve of the hydraulic control valve, as well as changes in the operating conditions of the hydraulic drive. As a result of theoretical researches, on the basis of mathematical modeling of working processes, combinations of design parameters of the hydraulic lock and the spool of the overflow valve were identified, which ensure the stability of the hydraulic drive in the mode of regulating the flow of the hydraulic motor. In particular, these are such parameters as the stiffness of the springs of the hydraulic lock and the overflow valve, the diameter and angle of inclination of the edge of the overflow valve spool, the area of the radial holes and the auxiliary choke of the overflow valve. It was also determined that in this mode, the stability of the hydraulic drive will be ensured under conditions of a load pressure of up to 20 MPa, a hydraulic motor flow rate of 100 l / min and a working fluid temperature of 80 °C.

Investigation on the dynamic performance of a new semi-active hydro-pneumatic inerter-based suspension system with MPC control strategy

This study presents the nonlinear modeling and model predictive control of a new semi-active hydro-pneumatic inerter-based suspension system (SAHPISS) for the first time. Unlike the traditional semi-active hydro-pneumatic suspension, a fluid inerter is added to the semi-active hydro-pneumatic suspension and a better damping effect can be achieved by adjusting the opening of the hydraulic control valve. First, an accurate analysis modeling of SAHPISS that considers the fluid hydraulic pressure drop, oil-gas nonlinearity and inerter nonlinearity is carried out. Then, a two-stage hierarchical control scheme based on MPC control strategy is proposed for SAHPISS to reduce calculation times of the system and the use rate of the hydraulic control valve and improve the working life of the hydraulic control valve under the consideration of suspension performance requirements. The results of the numerical simulations and experiments prove that the proposed new structure optimizes the low-frequency effect, has a high-frequency effect of the semi-active hydro-pneumatic suspension and verify the effectiveness of the control method.

Development of a hydraulic control valve with asymmetric variable lap spool controlled by a linear/rotational two-degree-of-freedom actuator

Development of a hydraulic control valve with asymmetric variable lap spool controlled by a linear/rotational two-degree-of-freedom actuator

DINAMICA REGLĂRII PROPORȚIONALE A VITEZEI VERSUS SERVOREGLAREA VITEZEI DEPĂNĂTORULUI DE FURTUN /CABLU AL TAMBURULUI

This article presents and analyses in two cases the dynamic performance of regulation and control of the linear speed of an electro-hydraulically driven mechatronic axis. In the first case, the flow control is performed with a proportional hydraulic directional control valve, while in the second case the control is performed with a servo-valve. The linear mechatronic axis is part of a complex subsystem used in both agriculture and industry that allows the precise winding of a hose / cable on a drum with the help of a spooling device, which conditions the positioning of the hose. The speed control of the hydraulic cylinder with bilateral rod on whose liner the spooling device is fixed is performed in a closed loop with the help of transducers and a programmable controller (PLC).

Design and Development of Hydraulic Control Valve Testing Machine

Design and Development of Hydraulic Control Valve Testing Machine

A Large-Flowrate On–Off Valve with Hollow Structure for High-Frequency Hydraulic Vibration and Impact System

In high-frequency hydraulic vibration and impact systems, the high-speed reciprocating motion of the impact piston, as controlled by the main valve, transfers energy to the target. Therefore, the main valve must have a fast response speed and strong flow capacity. A novel two-stage large-flowrate on–off valve is developed in this study. The first stage is a small-flowrate servo valve, and the second stage is a large-flowrate hydraulic control valve with a hollow spool. The hollow structure not only reduces the quality of the spool and improves the valve dynamic characteristics but also improves the flow capacity and reduces the pressure drop at the valve port. A structural strength simulation is performed, and the deformation and stress of the spool are calculated. Then, the internal flow channel is extracted and the pressure drop characteristics of valve are obtained by simulation. To obtain the dynamic characteristics of the valve, the control equations of the valve are established, and the simulation model is built in Simcenter Amesim software. Then, the structural parameters of the valve body are optimized in this model. Finally, a prototype is developed for hydraulic vibration and impact systems. The experimental results show that the prototype works well, the opening time of the second-stage valve is within 6 ms, and the port pressure drop at a flow rate of 1000 L/min is only 30% of the conventional opening and closing valve of the same diameter.

DINAMICA REGLĂRII PROPORȚIONALE A VITEZEI VERSUS SERVOREGLAREA VITEZEI DEPĂNĂTORULUI DE FURTUN /CABLU AL TAMBURULUI

This article presents and analyses in two cases the dynamic performance of regulation and control of the linear speed of an electro-hydraulically driven mechatronic axis. In the first case, the flow control is performed with a proportional hydraulic directional control valve, while in the second case the control is performed with a servo-valve. The linear mechatronic axis is part of a complex subsystem used in both agriculture and industry, that allows the precise winding of a hose / cable on a drum with the help of a spooling device, which conditions the positioning of the hose. The speed control of the hydraulic cylinder with bilateral rod on whose liner the spooling device is fixed is performed in a closed loop with the help of transducers and a programmable controller (PLC).

Comparison between two Hydraulic Control Valves Systems for Leakage Minimization in Water Distribution Networks Using Multi-Objective Memetic Algorithm . Dept C.(Irrigation )

This paper optimizes the selection, number, location, and sizing of hydraulic devices with the purposes of leakage reduction in water distribution network (WDN). A multi-objective memetic algorithm is adopted to effectively minimize the leakage problem in WDN through the regulation of two different hydraulic control valves systems: throttle control valves (TCVs) and flow control valves (FCVs). Two objective functions are simultaneously considered: the first one is to minimize the total leakage in the network and the second objective function is represented by the minimization of the number of valves (a surrogate for establishing valves cost) while accomplishing the required nodal pressure head restrictions. The great advantage of this study is that, in one run, several trade-off optimal solutions are acquired with a different level of compromise between the two objectives. Each solution from these optimal ones consists of minimum number of suggested valves, the best locations for the valves and optimum valves settings. The performance of the developed optimization model is evaluated by its application on a well-known WDN from literature. Then, the developed optimization model is applied on a real WDN of a new city, Egypt. Results show that the hydraulic performances of the two hydraulic control valves systems in leakage reduction are almost agreement for the same valves number, and the TCVs system is relatively better than the FCVs system

Comparison between two Hydraulic Control Valves Systems for Leakage Minimization in Water Distribution Networks Using Multi-Objective Memetic Algorithm

This paper optimizes the selection, number, location, and sizing of hydraulic devices with the purposes of leakage reduction in water distribution network (WDN). A multi-objective memetic algorithm is adopted to effectively minimize the leakage problem in WDN through the regulation of two different hydraulic control valves systems: throttle control valves (TCVs) and flow control valves (FCVs). Two objective functions are simultaneously considered: the first one is to minimize the total leakage in the network and the second objective function is represented by the minimization of the number of valves (a surrogate for establishing valves cost) while accomplishing the required nodal pressure head restrictions. The great advantage of this study is that, in one run, several trade-off optimal solutions are acquired with a different level of compromise between the two objectives. Each solution from these optimal ones consists of: minimum number of suggested valves, the best locations for the valves and optimum valves settings. The performance of the developed optimization model is evaluated by its application on a well-known WDN from literature. Then, the developed optimization model is applied on a real WDN of a new city, Egypt. Results show that the hydraulic performances of the two hydraulic control valves systems in leakage reduction are almost agreement for the same valves number, and the TCVs system is relatively better than the FCVs system.

Application of ultra-high molecular weight polyethylene in a hydraulic drive

The use of ultra-high molecular weight polyethylene (UHMW PE) for the manufacture of various parts, in particular cuffs for hydraulic drives, is proposed. The properties and advantages of UHMW PE in comparison with other polyethylene materials are considered. Keywords ultra-high molecular weight polyethylene, hydraulic pump, hydraulic motor, hydraulic control valve, hydraulic oil, low temperature. cvetkoffmax@mail.ru

Trajectory control for tire burst vehicle using the standalone and roll interconnected active suspensions with safety-comfort control strategy

The lateral pulling of tire burst vehicle results in accident and fatality on the highway due to its sudden C.G displacement of the vehicle. Improper steering input leads to detach wheel from vehicle and rollover accident due to the weight transfer towards the flat tire. Therefore, this paper attempts to reduce the lateral velocity and its displacement of the vehicle by producing the force through suspension actuator within the suspension limitation and without affecting the steering characteristics. For the analysis, 4-axle truck with velocity controller and steering system incorporated model was built in AMESim environment, which is exported into Matlab/Simulink for the co-simulation. Hydraulic control valve integrated standalone and roll interconnected active suspension scheme’s state space model was identified in Matlab through simple identification method for the comfort and safety MPC controller design. Finally, the results of passive system with Anti-roll bar (ARB) and without ARB, passive and active roll interconnected suspensions, comfort and coordinated control standalone active suspension system are comprised to illustrate the effectiveness and its control strategy. In addition, this work showcased the motion trajectory of vehicle with a flat tire on running over highway with and without steer maneuver.

Mathematical modeling of a hydraulic drive for leveling the support table of a robotic drilling platform

The principle of moving a hydraulic drilling platform is described. To study the dynamics of transient response processes of hydraulic drive for leveling, a mathematical model was created. The structural diagrams of mathematical models of the actuator and hydraulic control valve are given. The time dependences of the spool positions of the hydraulic control valve and the hydraulic cylinder rod are presented. The dependences of pressure changes in the rod and piston cavities of the hydraulic cylinder are presented.

Development of the concept of recurrent metamodeling to create projects of promising designs of mining machines

In the work on the example of a tunnel erector, the concept of recurrent metamodeling is determined which allows engineering new designs of mining machines. In this case, the metamodel of their entire family is associated with the family of models of machine nodes. The effect of various laws of movement of the erector devices is analyzed and it is proved that its minimum time is observed under conditions of compliance with the U-shaped law. A mathematical model of the hydraulic drive of the erector devices has been developed, which allows, taking into account any options for moving the point mass, to determine the law of control of the movement of the spool of the hydraulic directional control valve (DCV) in relation to the laminar and turbulent type of liquid flow. The erector device metamodel was created using the algorithmic language MATLAB Simulink.

Energy Management of Low-Pressure Systems Utilizing Pump-Unloading Valve and Accumulator

In the context of improving energy efficiency and fuel consumption of mobile hydraulic equipment, it is important to analyze all the sources of power loss occurring within the hydraulic systems. While plenty of analyses have been performed on the working implements and the main transmission systems, very little attention has been paid to low-pressure (LP) systems until recently. LP systems are required on closed-circuit hydraulic systems to replenish losses, provide cooling flow, and maintain a pilot pressure necessary to operate hydraulic control valves and variable displacement units. It is shown that these circuits, which are often thought to have minimal impact on power consumption, actually cause significant, continuous power loss. A new method of power savings in these circuits is investigated through management of charge pump flow by application of an accumulator-sense pump-unloading (ASPU) valve. This work further proposes the combination of a split LP architecture with an ASPU valve. Three systems are simulated using Simcenter Amesim® and MATLAB/Simulink®. Using realistic duty cycles and unit loss models on a circuit for mobile off-road hydraulic equipment, it is shown that a standard LP system can consume about 5 kW of power. Power savings of up to 65% over a standard LP system are demonstrated by the proposed architecture.

Improvement of Energy Regeneration for Hydraulic Excavator Swing System

A novel energy regeneration swing system is proposed for hydraulic excavator in this paper to reduce the energy consumption. Two independent accumulators are proposed for use in the hybrid swing system. The combined control of hydraulic motor displacement and flow control valve and a variable accumulator control strategy were proposed to improve the energy regeneration efficiency and ensure the system performance. A testbench was set up, and experiments were conducted. The experiment verified that the energy regeneration efficiency of the proposed system ranged from 23 to 56% in different conditions.