Research Papers

Energy Efficient Linear Drive Axis Using a Hydraulic Switching Converter

[+] Author and Article Information
Helmut Kogler

Linz Center of Mechatronics,
Altenberger Strasse 69,
Linz 4040, Austria
e-mail: helmut.kogler@lcm.at

Rudolf Scheidl

Institute of Machine Design and
Hydraulic Drives,
Johannes Kepler University,
Altenberger Strasse 69,
Linz 4040, Austria
e-mail: rudolf.scheidl@jku.at

1Corresponding author.

Contributed by the Dynamic Systems Division of ASME for publication in the JOURNAL OF DYNAMIC SYSTEMS, MEASUREMENT, AND CONTROL. Manuscript received August 4, 2015; final manuscript received April 4, 2016; published online June 8, 2016. Assoc. Editor: Yang Shi.

J. Dyn. Sys., Meas., Control 138(9), 091010 (Jun 08, 2016) (11 pages) Paper No: DS-15-1366; doi: 10.1115/1.4033412 History: Received August 04, 2015; Revised April 04, 2016

Digital hydraulics uses simple and cheap on/off valves in order to replace expensive proportional valves. Furthermore, with fast switching hydraulic converters the energy efficiency can be raised compared to proportional valve control. The hydraulic buck converter (HBC) represents an energy efficient and cost-effective switched inertance system, because its inductance is realized by a simple pipe. In this paper, a prototype for a hydraulic linear cylinder drive controlled by an HBC is presented. Characteristic for this drive axis is that the HBC is directly mounted on the cylinder, which allows a reduction of the oil transport loss between the axis and the hydraulic power supply unit. Furthermore, piston accumulators are used for decoupling and pressure attenuation. Due to their robustness regarding the prepressure to operating pressure, the load pressure can be controlled arbitrary in the piston-sided chamber. The energy performance and the tracking behavior of the axis with a flatness-based control (FBC) are investigated by steady-state measurements and dynamic trajectories, respectively. The results are discussed and an outlook about further improvements of the concept is provided.

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Fig. 1

Electric and HBC schematics

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Fig. 2

CAD drawing of the linear converter axis

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Fig. 3

Schematic of the test rig under investigation

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Fig. 4

Two views of the test rig for measurements: (a) converter drive axis and (b) dead load and load cylinder

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Fig. 5

Steady-state characteristics of the HBC prototype: (a) measured velocity characteristics and (b) power characteristics

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Fig. 6

Efficiency characteristics of the HBC (shaded) compared to resistance control (HPD, white)

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Fig. 7

Power characteristics of complete drive axis: (a) output power at the piston and (b) input power of HBC versus HPD

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Fig. 8

Comparison between HBC drive axis and HPD: (a) power improvement of HBC and (b) recuperation power of the HBC drive

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Fig. 10

Flatness-based control (FBC)

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Fig. 11

Ramp (v=±120 mm/s) without load cylinder: (a) extending movement and (b) retracting movement

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Fig. 12

Ramp (v=±50 mm/s) at a load pressure pL=60 bar in the load cylinder: (a) piston force FP = −1 kN and (b) piston force FP = −7 kN

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Fig. 13

Ramp (v=±50 mm/s) at a load pressure pL=90 bar in the load cylinder: (a) piston force FP = 9 kN and (b) piston force FP = 3 kN

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Fig. 14

Sinusoidal trajectory with different controllers and without load

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Fig. 15

Sinusoidal trajectory (P-controller) at different load pressures

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Fig. 16

Sinusoidal trajectory (FBC) at different load pressures



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