A 20 Years Research Journey in Fluid Power along with Deep ... Journey with Monika...Prof. Dr.31 May...

Final Assessment Meeting31 May 2005, Annecy le Vieux, France

A 20 Years Research Journey in Fluid Power along with Deep Respect and Friendship

with Monika

Prof. Dr.-Ing. Jürgen Weber,

Chair of Fluid Mechatronic Systems (Fluidtronics)

West Lafayette, June 5, 2019

Final Assessment Meeting31 May 2005, Annecy le Vieux, FranceProf. Dr.-Ing. J. Weber 2

Contents

Introduction – A New Idea 1998

IBIS 2002 - 2005

Displacement Control, Independent Metering

TEAM 2012 - 2015

Green Wheel Loader, Mining Excavator

Independent Metering – 2019 State of the Art

Back to the Future (Bauen 4.0)

Summary and Conclusion


Displacement Controlled Wheel Loader a simple and clever Solution

Monika Ivantysynova


• Simplification of System

- Costs

- Maintenance

Engx

u

Controller

• Better Use of Primary Energy

- No Throttling Losses

- Energy Recovery

• Powerful Dynamic System

and Easy to Control

Engx

LS

Controller

p

Valveless Actuator - Advantages


• Control via PC

• Electric driven pumps (Oilgear 10.8 ccm and Hydromatik A10VSG 10 ccm)

• Analogue and CAN-Bus position sensors

Stationary Wheel Loader Test Rig L5

DC-EM3700 rpm

37 kW

M, n

M, n

Wheel loader with 0.5 m3 bucket capacity


Stationary Wheel Loader Test Rig L5

f2

f1

Me1,n

Me2,n Load

Lifting

l1 = 3 m

Tilting

l2 = 2 m

PC Control with Transputer Card

u1

u2

f1

f2

u1

u2


High Load Stiffness

Pilot Operated Check Valves work properly

System Step Response under Load Change


Electrohydraulic

pump control

Eng

1

4

2

+FL

+x-xcom

3

5

a

b

7

8

A

B

Concept successfully tested !

Valveless Linear Actuator - Concept


IBIS

Advanced Multi-Functional Machinery

for Outdoor Applications

Project start: 1st of April 2002

Project duration: 36 month

Programme: FP5 “Competitive and Sustainable GROWTH”

Final Assessment

31th of May 2005


IBIS – Main Aims of the Project

Innovative Design and Interfaces for multi-functional

Mobile Machinery with Flexible Boom StructuresI.

II.Alternative Energy-efficient Hydraulic Actuator Technologies

- CV: Cartridge Valve Technology

- DC: Displacement Control

- HT: Hydraulic Transformer

III.Control Concepts for

- Advanced Intelligent Hydraulic Actuators

- Automatic Motion Control for Flexible Boom Structures

IV. Condition Monitoring – on-board Diagnostics & Prognostic Methods


Technology Platform - Wheel Loader

O&K

- Provision of machine structure

- Machine field tests

TuTech

- Actuator integration

- Actuator control

- Actuator steady-state and dynamic tests

CRF

- Sensor implementation

ACTIA

- Diagnostic hardware implementation

APS

- Diagnostic software implementation

- Test of diagnostic system

Responsible: Prof. M. Ivantysynova

DC Technology

&

Control

Monitoring

Failure prevention


Wheel loader 9 tons

Engine max. 82 kW at max. 2200 rpm

Normal bucket capacity 1.5 m

Working hydraulics / Functions:

Lifting & Tilting, Parallel Fork Lift, Floating,

Return to Dig, Lift Limitation, 3rd Function

Hydraulic steering system

Hydrostatic cooling and

brake system

Technology Platform – Wheel Loader

Overall functionality

needs to be realized by

the new system


Displacement Controlled

DCCircuit Diagram

Working functions:

Pump 1,2: 75 ccm

Steering:

Pump 3: 28 ccm

with hydrostatic

transmission

Engine

Aux. Pumps

Lifting

TiltingPropel

Drive


Valveless Pump Configuration

SAE1 ports

with shut-off

valves

Pilot operated check

valves as cartridges

High pressure

relief valves

Parallel ports for

OLS

Low

pressure

connection

Auxiliary mounting pad

Measurement ports

Standard

housing

Rapid prototyping

endcap

with valveless

integrated

functionality


valveless

standard

Field test programme side by side:

standard and valveless system

Engx

u

Controller

Engx

LS

Controller

p

Machine Comparison Test


Truck loading – short & long cycle

Stop

Stop

StopStop

valveless:

15 % less

fuel consumption



valvelessstandard

Parallel fork lifting

Easier to Operate

Excellent Controllability



Final Results



Technology Platform - Mobile Excavator

Responsible: Dr. J. Weber

O&K

- Provision of machine structure

- Machine software frame and controller

- Assembly of multi-functional boom structure

- CV actuator integration

- Machine steady-state and field tests

CRF

- Motion control implementation

TuTech

- Actuator control implementation

- Test of actuator dynamics

ACTIA

- Actuator control hardwareCV Technology

&

Control

Reconfigurable

boom structure


Cartridge Valve Technology

High dynamic response

Zero leakage

Usable for different applications as

- safety valve

- pressure relief valve

- flow control valve

- pressure control valve

Main Cartridge

Pilot Valve

Pilot Oil Notch


Attachment Routing and Piping

High pressure

line

Low pressure

(return) line

Cartridge Valve

Main Stage

Pilot Valves


Main Stage and Pilot Stage - Measurements

p = 220 bar, Q = 0 - 360 l/min

stability achieved

Main spool version III

Pilot Flow increased

(about 15 l/min)

Hysteresis has been reduced


Improvements of Main Stage

Goals / Results:

- Improvement of Stability

- Less sensitive on vibration

- Improvement of resolution in

different pressure ranges

- Increase of stroke to

12 mm does not lead to

improvements


v1Logic

Controller

v2

v3

v4

BoomCylinder

+-PID

Control Logic

θcom eθ θ΄com

θθ΄

pA,pBpS,pT

PID Control with

Non-linear Compensation for each valve

1/s

Valve Block

Feedback Pressure Signals

Feedback Position Signals

• SIL2 / AK4

• IP 67

• 5x PWM Output (1A)

with current feedback

• 2x digital Output (1A)

• 4x analog Input

• 4x digital Input

• 2x CAN

Actuator Requirements


Cylinders with integrated Sensors

Stick Cylinder

Boom Cylinder

Bucket Cylinder

Operating Conditions• Rod Pressure Rating: up to 530 bar

• Shock Rating: 50 g

• Vibration Rating: 5 g

• Measuring Range higher 1000 mm

Sensor element

Position magnet

Signal converter

Sensor Data• magnetostrictive principle

• No-contact Sensor

• No mechanical wear and tear

• resolution < 10 mm

• Linearity up to 0,01%

• Repeatability 0,001%


Semiautomatic Control Operation

Function Samples

ProfilingLeveling

Control

T1

T2

T3

Sensors

Profil Parameter

Display

Motion Control – Semiautomatic Operation

ControlCylinder 3

Joystick

ControlCylinder 2

ControlCylinder 1

SlideCCEFP Conference June 4-7, 2019LFD, DresdenProf. J. Weber

„The Green Wheelloader„

Research Project 2012 - 2015


State of the Art and Project Goal

28

Working hydraulics

M M

LS NFC

Transmission

Sum

mie

r-

ge

trie

be

an abPTL

Schalt-

getriebe

an ab

hydrodynamic hydrostatic

Diesel Engine

Hybrid Module

Transmission

Working hydraulics

Diesel Engine

Displacement control

Power split

optimized engine

State of the Art Available Concepts Project Goal


ECU

Maschinensteuerung

Systemstructure

29

Hybrid Module

Power Split

Displacement Controlled

Working Hydraulics

Diesel

engine

Integration

and Assembly

Torq

ue

Engine Speed600 1000 1400 2200U/min

0

400

800

1200

1600

Nm Standard Engine

Optimized Engine

Speed v

Tota

l E

ffic

iency h

Hydro Dynamic Power Split

NDLS

VC DC

Energ

y

Conum

ption

HP LPN2

HP

LP

conv. Double Rod

Engery

Density

Efficiency

Control /ease of use

Productivity

Maintain Machine Functionality


Sp

ecific

Co

nsu

mptio

n

Operating strategy

30

▪ Decoupling of the diesel engine from the user input

▪ Dependent on the demand of the subsystems

▪ Engine speed control strategies:

▪ Quasi-constant, low speed

▪ Optimum speed in terms of load and efficiency map

Higher engine power capacity, lower losses

ntarget

Engine

Engine

Control

Attachment

Control

Machine Control

Drive

Control

Steering

Pow

er

Managem

ent

Hybrid

Control

Drive System

Hybrid

AttachmentECU

ECU

ECU

ECU

ECU

900 1200 U/min

Engine Speed nDiesel

1800

1800

Nm

1200

900

600

300Torq

ue

MD

iesel

0

-300

Short Load Cycle

600

900 1200 U/min

Engine Speed nDiesel

1800

1800

Nm

1200

900

600

300

Torq

ue

MD

iesel

0

-300

Short Load Cycle

Specific

Consum

ption

600


Model Creation

Simulation of the Process interaction

31

Test Rig

ParameterizationValidation

Fx Meas.

Fx Simulation

Fy Meas.

Fy SimulationPro

cess F

orc

e F

Comparison of the Process Forces


Experiments

32

Test Rig for the power split drives

Measurement

Simulation

η

Ratio

To

rqu

eT

orq

ue

▪ Effiencieny measurements to validate the simulation

▪ Analysis of the gear transmission dynamics

Hybrid

Load /

Output

Input

PSD


Development Stations

Research &

Development Integration and assembly

at Liebherr, Bischofshofen Transport to Dresden

Start up, Dresden

Rollout & and first test

April 2014

October 2013

August 2014

January 2012

Project Start

Machine adjustement and testing,

gravel quarry near Dresden

November 2014

Source: http://www.qomet.de

33


Testing

In real operating conditions with trained drivers

34


Testing

Results in comparison to the reference machine

0 7 14 21 s 350

50

100

kW

200

Zeit

Mo

torl

eis

tun

g 0 7 14 21 s 35-8

-4

0

km/h

8

Zeit

Ge

sch

win

dig

ke

it

0 7 14 21 s 35-250

-125

0

kN

250

Zeit

Zu

gkra

ft

8

Drive S

pee

d

km/h

0

-4

-8 Tra

ctio

nF

orc

e250

kN

0

-125

-250200

Engin

e P

ow

er

kW

100

50

00 7 14 21 s 35

Time

v

FTrac

PEngine

0 10

20

40

60

80

100100

%

80

70

60

50

-10%

Fuel co

nsum

ption

0 10

20

40

60

80

100

500 1000 2500U/minEngine Speed

0

500

1000

2000

Nm

To

rque

500 1000 1500 U/min 25000

500

1000

Nm

2000

1500

Reference

Machine

Green

Wheel

loader

Simulation

1 2 43 5

35


DC Mining Excavator Machine

36

Working Hydraulics

Actuators

• 2 Boom Cylinders (Red)

• 2 Stick Cylinders (Blue)

• 2 Bucket Cylinders (Green)

• 2 Clam Cylinders (Orange)

• 2 Swing Motors (Yellow)

• 4 Travel Motors (Purple)

CAT 6030 (Bucyrus RH-120E)

• Motor power: 1140 kW

• Weight: 287 t

• Max. Lifting force: 1370 kN

• Max. Break force: 920 kN

• Working Area: Mining


Energetic Overview Standard Machine

37

Energy Flow over one Cycle

En

gin

e E

nerg

y 1

00

%

Actuators >25 %

Valve losses > 30 %P

um

p losse

s

Oth

er

pa

rasitic

lo

sses

Mete

r-In

Mete

r-O

ut

Pre

-ch

arg

e v

alv

e

OC

-

Channel

Auxiliary > 25%*

* Based on maximal power output of aux. drives - worst case scenario

Line losses < 15 %


New Open Circuit DC System

38

0 10 20 30 40

• No throttle losses

• No OC-losses

• Less line losses

• Recovery potential

Savings potential per Cycle (EVKM, mech =100 %)%


30s Cycle - (Sim vs. Sim)

39

30 s Ideal Cycle

• Energy recovery: 3.2 %

• Energy savings: 43 % (hydraulic only)

1.2

1

0,6

0,2

0

Positio

n x

Time

30s Cycle Positions

0 5 10 15 20 25 s

Time

-

400

10

5

0

[MJ]

1200

600

0

[kW]

800

15

-200

∑E

Pu

mp,h

yd

∑P

Pu

mp,h

yd

30s Cycle: Hyd. Pump Power

0,8

0,4

30

Boom ( DC , OC)Stick ( DC , OC)

Bucket ( DC. , OC)Swing ( DC. , OC)

400

200

DC (Sim)OC (Sim)

DC (Sim)OC (Sim)

7MJ (43%)

30s Cycle: Hyd. Pump Energy

0 5 10 20 25 30s15

Folie LFD, DresdenProf. J. Weber

Technology OverviewIndependent Metering Systems

Efficiency

Dynamic

Integration Universal

Flexibility

Software

IM

Freely configurable flow paths

(flow regeneration)Adaptable operating

characteristic

Universal Valve Elements

Functional integration

(Load holding)

Decentral installation

Dynamic behavior

(extended control

capabilities)


Machine Integration

Source: Liebherr

Base-

structure

Structural

variants

Various Machine-types & requirements

System development Valve structure concepts

Aspects of integration

- Installation space- Valve technology- System Control

- Costs- …


Valve Structures

Circuit Variants

Pro

p.

normal

meter in / out

+ low pressure

regeneration

+ high / low pressure

regeneration

Short circuit

valve

Pro

p. / S

wit

ch

p0 pT

p0 pTpT p0 pTpT

p0 pTpT

p0pT pT p0pT pT

p0 pTpTp0 pT

p0 pT


Control architecture

2

1

2221

1211

uu

sGsGsGsG

px

K1

K2

stable

unstable

Stability

region

G11

G21

G12

G22

u1

u2 x2

x1

K2

K1 G11

G21

G12

G22

u1

u2 x2

x1

K

G11

G21

G12

G22

u1

u2 x2

x1

K22

K11

K21

K12

cross coupling behaviorlow high

• MIMO Multiple Input / Multiple Output System

• Strength of cross coupling defines control system requirements

Decentralized Control

2 separate SISO Systems

Linear / Nonlinear decoupling

Feedforward Control

Multivariable Control

e.g. flatness based Control

ω

RGA

1

0

Coupling

measures

-200 -100

Re(p)

-250 -200 -150 -100 -50 0-200

-100

0

100

200

200 100

0.80.6 0.4 0.2

0.80.6 0.4 0.2

0

Im(p

)

Frequency

domain


Energy efficient operation

depending on load direction

different modes are feasible

v/vmax

F\Fmax

vNM vregvNMvreg

FNM

Freg

αFNM

FNM

Pmax

1

-1

1-1

II I

III IV

v

FLastFLast

v

v

FLast

v

FLast

Power loss intlet

Power loss outlet

Mechanical work



Study Wheel loader working hydraulics

• Possible energy savings

Normal meter in / meter out

+ Low pressure regen. incl. short circuit valve

lpREGsc

+ Low pressure regen. excl. short circuit valve

2

1

3

21 3

2

Danger of

cavitation

lpREGo

3

Ref

eren

z: L

UD

V

Bas

is: N

Mi

NM

i + X

NM

NM

i + lp

RE

Gsc

NM

i + lp

RE

Go

NM

i + h

pR

EG

sc

NM

i + h

pR

EG

i

NM

i + h

pR

EG

o

NM

i + N

Mo

Alle

Mo

di

0

0,2

0,4

0,6

0,8

1

spez. Z

yklu

senerg

ie

E

/ELU

DV

1,000,89 0,89

0,72

0,88 0,850,88 0,88

0,84

0,68



1: throttle losses inlet

2a: effective power

2b: moving load

3: throttle losses outlet

Introduced mech. Power – throttled

at inlet and outlet valve edges

pP

um

p (t*

)

1

2a

3

1 1, 2b, 3

3

Qpump(t*)

Boom

Stick

1

1, 2b, 33

pP

um

p (t*

)

Qpump(t*)

1

2a

3

StickBoom

Energy

1

1

3 3 2

2

Conventionell Independent Metering0 2 40

2

4

yTCP

[m]

0

TCP

vTCP

xTCP(t*)

Leveling cycle

xTCP [m]

Study and measured Excavator working hydraulics


Functional Safety

Independent metering for power assisted steering systems

• electrical drives offer very often integrated safety functions

• leads to an easy system integration for OEM

• benefits of IM structures in steering systems:

• driver assisted steering

• high safety level due to extended control intervention

ref.: HNF

ref.:

ww

w.fe

nd

t.co

m

pump

tank

steering unit

P

T

LAG

…

…

…

release valve

meter-in right

meter-out right

meter-out left

meter-in left

angle sensor

angle sensor

electr. control unit

FV

VRP

VRT

VLT

VLP

φswφwECU

…

…

…

…

…

…

…

…

P T

VRP VRT VLP

FV

VLT

LAG

φw

φsw

ECU

R/NR

….Back to the future

Joint Research Project BAUEN 4.0

Joint Research - BAUEN 4.0Prof. Dr.-Ing. Jürgen WeberWest Lafayette, June 5, 2019

Slide2

1910 – Vision of a construction site in the year 2000

www.sabotagetimes.com/life/a-vision-of-the-future-from-1910

shown in the world exposition in Paris 1910


Slide3

Joint Research Project „BAUEN 4.0“

… fully digitized, highly automated, highly customizable construction site

… efficiency and productivity gains through assistance, automation and data collection - operator as machine coordinator

… new business and value chains technological leadership

Vision

… holistic simulation & optimization of today's and future construction machinery and construction processes through massive networking and communication


Slide4

5G Communication of the Machines and the digital construction site

Assistence

Machine cooperation composite automation

IOT-capableComponents

Migration of heterogeneous

technologies

Workspace monitoring

Remote handling, autonomy

Machine-services

Prerequisite for an efficient and capable automation


Slide5

5G Machine andConstruction Site Networks

Sensor data fusion

Networking and Communication

Automation/ autonomous Machines

Integration of data planning and processing

Condition Monitoring

Processes of the digital construction site

Connected andautomated machines

Holistic approach to establish Industry 4.0 technologies

Cloud integration

Distributed intelligenceReliable & secureData transfer

wirelesscommunication

Remote Control

Operator assistance

Automation

Sensor technology Logistic-, Construction Data

environment recognition

remote management

digital twin

wirelesscommunication


Slide6

Smart Metering

OptimizingMonitoring

Assistance Automation

DigitalTwin

Machine capability to communicate, automationSoftware-based networking controllers, appropriate architecture for electronics and control,automation-oriented system design,

Assistance & virtual usability/operationIntegration of sensors, digital model and environmental information

Digital Machine Model / TwinOptimizing, real-time analysis

Machine servicesCondition monitoring, failure prediction, diagnosis, maintenance & repair

Implementation & testing on demonstrators

Major Project TopicsConnected and automated machines


Slide7

© Liebherr

Machine and construction site dependent 5G communication infrastructureInclusion of external / ambient sensor unitstemporary on-site or available cellular networks

Communication units & systemscompatible to communication standards used today in the machines (CAN / Ethernet)

Machine and construction site optimized cloud concepts and solutionsMobile Edge Cloud, Regional-Cloud, Global-Cloud

Integration of solutions in demonstration scenarios for civil engineering

Standards for message formats and communication protocols Inclusion of RAMI 4.0

Major Project Topics5G Machine and Construction Site Networks


Slide8

Major Project TopicsProcesses of the Digital Construction Site

Construction site process model - production synchronousdigital twin, 5D-BIM construction site, formalized workflow descriptions

Digital construction planning for civil engineeringReal-time status information of actuators and entities, information and task coordination of the machines

Quality and efficiency management, optimization of processes via holistic simulationsAlgorithms to analyze and evaluate the building process efficiency based on the real-time state information


Slide9

Main controller with subsystem architecture

(as unchanged as possible)

Embedded Machine Cloud(local on the radio module)

On Site Cloud(local on construction site)

Global Cloud(via Internet)

Attachments, Sensors,Displays, Material,

Machines, Subsystems

AxxDISPLAY

Interface to the main controller / subsystem

(CAN, Ethernet application specific)

5G Connectivity-Moduleuniform interface

Machine / Device level

On siteserver

External Server

Digital construction planning

Tracking & Tracing

ExternalServices

Monitoring,automation

Device interfacesAnd services

5G Machine and Construction Site NetworkingDemand-specific networking solutions


Slide10

Connectivity ModuleEmbedded cloud

Additivecontroller

MainController

Machineinterface

5G5G

Environmentsensors

Control roomvisualization

CAN

LAN/UDP

5GLAN

On-Site cloud

Router

SubsystemController

Communication and Control Architecture on Machine level


Slide11

Results and Benefit

Automation, assistance, digitization and optimization of machines and construction processes,technologically proven solutions

Testing / establishment of 5G communication technologies for the construction site, for the construction machine - future innovative business and value creation models

Experimental construction site for research and development activities related to the digitization and automation of the construction site environment

Development / publication of an information platform with the findings, solution principles and application examples


Slide12

© Lisa-Marie Lüneburg

Contakt:

Prof. Dr.- Ing. Jürgen [email protected]+49 351 463 33559

André [email protected]+49 351 463 33707

Oliver [email protected]+49 351 463 33706

mailto:[email protected]




Slide13

Technische Universität Dresden | Institut für Mechatronischen MaschinenbauProfessur für Fluid-Mechatronische Systemtechnik

Prof. Dr.-Ing. J. Weber | Tel. 0351- 463 33559 | [email protected]

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A 20 Years Research Journey in Fluid Power along with Deep ... Journey with Monika...Prof. Dr.31 May...

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