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New Challenges in Electrohydraulic Control System and Energy Saving

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A special issue of Energies (ISSN 1996-1073). This special issue belongs to the section "F: Electrical Engineering".

Deadline for manuscript submissions: closed (28 April 2023) | Viewed by 19784

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Special Issue Editor

Dr. Hu Shi

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Guest Editor

School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an 710049, Shaanxi, China
Interests: mechatronics; mechanical engineering; control systems; tunneling; manufacturing engineering; fuzzy control; motion control; fluid power

Special Issue Information

Dear Colleagues,

Electrohydraulic control systems are widely used in machinery due to their advantages in power transmission flexibility and adaptability to extreme conditions. From intelligent robots to precision machine tools, construction machinery or vehicles, it plays a similar role to that of the muscles in the human body and determines performance as well as reliability. For a long time, energy efficiency has been an everlasting challenge and issue that challenges the systems developed in many fields. For example, the energy loss of electrohydraulic systems of large tunnel-bearing machines with thousands of kilowatts definitely degrades the local environment of workers through an increase in temperature, and energy-efficient hydraulic systems on aircrafts reduce the weight of the power package directly. In some areas, electric drive systems are often used to replace fluid control systems to find a compromise and avoid energy efficiency issues. Therefore, the energy saving and management of electrohydraulic systems have attracted research interest in this field.

On the other hand, with the development of industrial technology, electrohydraulic drives are also seeking a way to overcome their disadvantages compared with their counterparts. Intelligent control is integrated increasingly deeply into the electrohydraulic system to yield digitalization, networking and smartness. Emerging applications are extending into flexible drives, bionics and biomedical engineering, etc. Power control and energy regulation are always implicated in such applications and the implementation of electrohydraulics.

This Special Issue focuses on these important research areas in order to surpass the limitations of the traditional electrohydraulic control system and promote energy saving and smartness. Contributions are especially, but not only, encouraged to address the following topics:

Review of energy saving strategies for electrohydraulic control systems;
Design and control strategies of electrohydraulic systems with high efficiency;
Energy saving-based optimization of electrohydraulic systems;
Innovative methods to apply smart materials to electrohydraulic systems;
Electrohydraulic components to enhance power transmission efficiency;
Approaches for harvesting energy from machines driven by electrohydraulic systems;
Integration of electrohydraulic systems into smart devices;
Electrohydraulic control system in the era of Industry 4.0;
Coupling analysis of electrohydraulic systems with multiphysics;
Microhydraulic system with high performance;
Electrohydraulic system operating under extreme conditions.

Dr. Hu Shi
Guest Editor

Manuscript Submission Information

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Keywords

hydraulic control system
energy saving
energy harvesting
system optimization
coupling analysis

Published Papers (11 papers)

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Research

Jump to: Review

12 pages, 3573 KiB

Open AccessArticle

Data-Based Flow Rate Prediction Models for Independent Metering Hydraulic Valve

by Wenbin Su, Wei Ren, Hui Sun, Canjie Liu, Xuhao Lu, Yingli Hua, Hongbo Wei and Han Jia

Energies 2022, 15(20), 7699; https://0-doi-org.brum.beds.ac.uk/10.3390/en15207699 - 18 Oct 2022

Cited by 6 | Viewed by 1156

Abstract

Accurate valve flow rate prediction is essential for the flow control process of independent metering (IM) hydraulic valve. Traditional estimation methods are difficult to meet the high-precision requirements under the restricted space of the valve. Thus data-based flow rate prediction method for IM valve has been proposed in this study. We took the four-spool IM valve as the research object, and carried out the IM valve experiments to generate labeled data. Picking up the post-valve pressure and valve opening as input, we developed and compared eight different data-based estimation models, including machine learning and deep learning. The results indicated that the SVR and DNN with three hidden layers performed better than others on the whole dataset in the trade-off of overfitting and precision. And MAPE of these two models was close to 4%. This study provides further guidelines on high-precision flow rate prediction of hydraulic valves, and has definite application value for development of digital and intelligent hydraulic systems in construction machinery. Full article

(This article belongs to the Special Issue New Challenges in Electrohydraulic Control System and Energy Saving)

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12 pages, 3373 KiB

Open AccessArticle

Study of the Thermal Insulation and Flow Field of Vehicle Front Exhaust Pipe

by Yuanhong Li, Qing Han, Dianxiu Xia, Linyu Gao, Jialei Hu, Hongyan Wang and Bin Yi

Energies 2022, 15(11), 3912; https://0-doi-org.brum.beds.ac.uk/10.3390/en15113912 - 25 May 2022

Cited by 7 | Viewed by 1470

Abstract

Exhaust is generated by engine flows through a turbocharger, front exhaust pipe, and selective catalytic reduction (SCR) post-treatment device. The structure of the front exhaust pipe affects the temperature, velocity, and turbulent kinetic energy of exhaust and the Sauter Mean Diameter (SMD) of urea water solution (UWS). A high temperature and turbulent kinetic energy in the exhaust will promote the decomposition of UWS, and further accelerate the evaporation and atomization effect of the UWS droplets. Therefore, in order for the exhaust to reach a high temperature and turbulent kinetic energy, a double-layered pipe structure with air insulation was designed. The flow field and the atomization of UWS in the double-layered pipe based on hydroforming processing was investigated through numerical simulation. The thermal insulation simulation was verified by the temperature measurement system and the temperature drops between the double-layered pipe and the volcanic rock-wrapped pipe were also compared. The results indicate that the temperature at the outlet of the designed double-layered pipe was 3.5% higher than that of a single-layered pipe with the same structure, and the velocity at the outlet of the exhaust of the double-layered pipe was 16.1% higher than that of a single-layered pipe. The maximum turbulent kinetic energy in the double-layered pipe was 71 times that of the single-layered pipe. The design is not only conducive to the mixing of UWS and exhaust, but can also improve the atomization performance of UWS. Full article

(This article belongs to the Special Issue New Challenges in Electrohydraulic Control System and Energy Saving)

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18 pages, 38404 KiB

Open AccessArticle

Fault Diagnosis Method of Waterproof Valves in Engineering Mixing Machinery Based on a New Adaptive Feature Extraction Model

by Rui Zhang, Jiyan Yi, Hesheng Tang, Jiawei Xiang and Yan Ren

Energies 2022, 15(8), 2796; https://0-doi-org.brum.beds.ac.uk/10.3390/en15082796 - 11 Apr 2022

Cited by 4 | Viewed by 1393

Abstract

Due to the complex working medium of oil in construction engineering, the waterproof valve in mixing machinery can easily cause different degrees of failure. Moreover, under adverse working conditions and complicated noise backgrounds, it is very difficult to detect the fault of waterproof valves. Thus, a fault diagnosis method is proposed, especially for the fault detection of waterproof valves as a key component in the construction of mixing machinery. This fault diagnosis method is based on a new adaptive feature extraction model, with multi-path signals to the improved deep residual shrinkage network–stacked denoising convolutional autoencoder (named DRSN–SDCAE). Firstly, the noisy vibration signals collected by the two vibration sensors are preprocessed, and then transmitted to the parallel structure improved DRSN–SDCAE for adaptive denoising and feature extraction. Finally, these results are fused through the feature fusion strategy to realize the effective fault diagnosis of the waterproof valve. The effectiveness of this method was verified through theory and experiments. The experimental results show that the proposed fault diagnosis method based on the improved DRSN–SDCAE model can automatically and effectively extract fault features from noise for fault diagnosis without relying on signal processing technology and diagnosis experiences. When compared with other intelligent fault diagnosis methods, the features extracted from multi-path inputs were more comprehensive than those extracted from single-path inputs, and contained more complete features of hidden data, which significantly improved fault diagnosis accuracy based on these fault features. The contribution of this paper is to learn fault features autonomously in signals with strong and complex noise through a deep network structure, which extends the fault diagnosis method to the field of construction machinery to improve the safe operation and maintainability of engineering machinery. Full article

(This article belongs to the Special Issue New Challenges in Electrohydraulic Control System and Energy Saving)

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15 pages, 13219 KiB

Open AccessArticle

Variable Structure Disturbance Observer Based Dynamic Surface Control of Electrohydraulic Systems with Parametric Uncertainty

by Shuai Li, Ke Zhu, Liang Chen, Yao Yan and Qing Guo

Energies 2022, 15(5), 1671; https://0-doi-org.brum.beds.ac.uk/10.3390/en15051671 - 23 Feb 2022

Cited by 3 | Viewed by 1085

Abstract

This paper focuses on the position tracking control issue of electrohydraulic systems (EHS). The dynamical model of EHS is introduced in the first place, based on which a type of Variable Structure Disturbance Observer (VSDO) is constructed for EHS to estimate the parametric uncertainty the EHS possesses. Then, a backstepping controller is designed under VSDO to realize the high precision position tracking purpose. To avoid the phenomenon of differential explosion, a dynamic surface control method is adopted in this paper, which improved the position tracking control performance of EHS. The proposed theoretical results are verified by numerical simulation and experiment to illustrate the feasibility. Full article

(This article belongs to the Special Issue New Challenges in Electrohydraulic Control System and Energy Saving)

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15 pages, 2721 KiB

Open AccessArticle

Improvement of Contact Force Calculation Model Considering Influence of Yield Strength on Coefficient of Restitution

by Xichun Liu, Wei Chen and Hu Shi

Energies 2022, 15(3), 1041; https://0-doi-org.brum.beds.ac.uk/10.3390/en15031041 - 30 Jan 2022

Cited by 5 | Viewed by 2643

Abstract

Aiming at the problem that the current coefficient of restitution model cannot effectively predict energy dissipation in the multi-body system collision process, a coefficient of restitution model considering the yield strength is proposed in this article. As an important parameter for energy loss and material deformation prediction during collision, the coefficient of restitution has an important influence on the accurate calculation of contact force. The current main coefficient of restitution models are compared and analyzed in this article. In view of the large difference between the results obtained by different models on the same parameter, through the use of ANSYS/LS–DYNA for dynamic simulation, the influence of different yield strengths on the coefficient of restitution is studied. Then, the article establishes a new coefficient of restitution model considering the yield strength combined with the J–G model, and verifies the effectiveness of the model in the article using experimental results. At the same time, the article compares the new coefficient of restitution model with the constant coefficient of restitution model, and further studies the effect of the coefficient of restitution on the dynamic results. Full article

(This article belongs to the Special Issue New Challenges in Electrohydraulic Control System and Energy Saving)

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16 pages, 6268 KiB

Open AccessArticle

Performance Analysis of Electro-Hydraulic Thrust System of TBM Based on Fuzzy PID Controller

by Weiqiang Wu, Guofang Gong, Yuxi Chen and Xinghai Zhou

Energies 2022, 15(3), 959; https://0-doi-org.brum.beds.ac.uk/10.3390/en15030959 - 28 Jan 2022

Cited by 5 | Viewed by 2157

Abstract

The tunnel boring machine (TBM) is widely used in tunnel construction projects. The thrust system plays a crucial role to drive the machine ahead and support gripper shoes stably while tunneling. More and more attention has been paid to the pressure and velocity regulation efficiency as the TBM advances in complex rock conditions to ensure the stabilization of the tunneling process. A thrust hydraulic control system, assembled with a proportional pressure reducing valve, is established with system operating parameters. The mathematical model of the thrust electro-hydraulic system is revealed. To improve the control characteristics of the thrust system, a self-tuning fuzzy PID controller is introduced in the pressure and velocity regulation procedures. After that, tests on a Φ2.5 m scaled TBM test rig are carried out. The test results show that the thrust system adopting the fuzzy PID controller results in less oscillation and a smoother regulation process. It takes less time to reach the target goal of pressure regulation with less vibration during the pressure regenerating periods, and both systems of conventional PID controller and fuzzy PID controller are qualified in velocity regulation movements. The proposed control methods show better benefits in reduction of vibrations and shorter time of regulation to stable conditions, which extends the machine’s life and affects the acceleration of the tunneling process. Full article

(This article belongs to the Special Issue New Challenges in Electrohydraulic Control System and Energy Saving)

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15 pages, 3732 KiB

Open AccessArticle

Control Performance Improvement of Hydro-Viscous Clutch Based on Fuzzy-PID Controller

by Xiangping Liao, Shuai Yang, Dong Hu, Guofang Gong and Xiongbin Peng

Energies 2021, 14(24), 8282; https://0-doi-org.brum.beds.ac.uk/10.3390/en14248282 - 09 Dec 2021

Cited by 2 | Viewed by 1655

Abstract

As a rotational speed controller, a hydro-viscous clutch (HVC) is usually used in the constant pressure water supply system to maintain the needed water pressure constant. However, when the hydro-viscous clutch is working, it often suffers from the problem of output rotational speed fluctuation since the spool of proportional relief valve can easily get stuck. Consequently, water pressure will fluctuate too. A special pump control system of HVC was proposed based on the Fuzzy-PID controller for the purpose of reducing the fluctuation rate. The MATLAB simulation was carried out according to the mathematical model and the results show that the Fuzzy-PID control strategy is superior to traditional PID control. The corresponding experiment was performed and the result indicate that through applying the Fuzzy-PID controller based pump control system, the rotational output speed fluctuation of HVC can be inhibited from ±60π to ±6π rad/min, and the water pressure fluctuation is dropped from ±0.1 to ±0.002 MPa. Full article

(This article belongs to the Special Issue New Challenges in Electrohydraulic Control System and Energy Saving)

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14 pages, 4290 KiB

Open AccessArticle

Analysis and Revision of Torque Formula for Hydro-viscous Clutch

by Xiangping Liao, Shuai Yang, Dong Hu and Guofang Gong

Energies 2021, 14(23), 7884; https://0-doi-org.brum.beds.ac.uk/10.3390/en14237884 - 24 Nov 2021

Viewed by 1647

Abstract

Hydro-viscous clutch is a speed-regulating device for heavy fans and water pumps. It has important engineering significance in the fields of soft-start for rotating machinery. More and more attention has been paid to its torque and control characteristics. This paper is focused on the torque formula for hydro-viscous clutch (HVC), assuming that multi-friction plates distribute ununiformly with different oil film thickness. A mathematical model of friction plates was constructed, then the distribution formula of the oil film thickness was obtained. A new expression was presented using a modified factor. Parameters such as pressure, viscous torque, and oil film thickness were obtained. The results show that each clearance of friction plates is not the same and the distribution of oil film thickness is influenced by pressing force, groove depth, angular ratio of groove/non-groove, and static friction force. To verify the proposed expression, relevant experiments were carried out on an HVC with multi-friction plates, and the experimental results indicate that the new expression is more accurate compared to the original one. Full article

(This article belongs to the Special Issue New Challenges in Electrohydraulic Control System and Energy Saving)

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19 pages, 8629 KiB

Open AccessArticle

Numerical and Experimental Investigation of a Semi-Active Vibration Control System by Means of Vibration Energy Conversion

by Chaoqing Min, Martin Dahlmann and Thomas Sattel

Energies 2021, 14(16), 5177; https://0-doi-org.brum.beds.ac.uk/10.3390/en14165177 - 21 Aug 2021

Cited by 3 | Viewed by 1927

Abstract

A vibration control concept based on vibration energy conversion and storage with respect to a serial-stiffness-switch system (4S) has previously been proposed. Here, we first present a rotational electromagnetic serial-stiffness-switch system as a novel practical vibration control system for experimental validation of the concept and, furthermore, an improved control strategy for higher vibration suppression performance is also proposed. The system consists of two spring-switch elements in series, where a parallel switch can block a spring. As an alternating mechanical switch, the experimental system uses two electromagnets with a shared armature. By connecting the armature to the rotating load or the base, the electromagnets decide which of the two spiral springs is blocked, while the other is active. A switching law based on the rotation velocity of the payload is used. Modelling and building of the experimental system were carried out. The corresponding experiment and simulation were executed and they matched well. These results prove that our serial-stiffness-switch system is capable of converting vibration energy and realizing vibration reduction under a forced harmonic disturbance. The effects of disturbance frequency, disturbance amplitude and sampling frequency on the system performance are shown as well. A position feedback control-based switching law is further put forward and experimentally verified to improve the repositioning accuracy of the disturbed system. Full article

(This article belongs to the Special Issue New Challenges in Electrohydraulic Control System and Energy Saving)

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12 pages, 5217 KiB

Open AccessArticle

Analysis of Dynamic Characteristics and Power Losses of High Speed on/off Valve with Pre-Existing Control Algorithm

by Qi Zhong, Xiele Wang, Geng Xie, Huayong Yang, Cheng Yu, Enguang Xu and Yanbiao Li

Energies 2021, 14(16), 4901; https://0-doi-org.brum.beds.ac.uk/10.3390/en14164901 - 11 Aug 2021

Cited by 11 | Viewed by 1722

Abstract

A high-speed on/off valve (HSV) is generally the core component of a digital hydraulic transmission system. Therefore, its dynamic characteristics often restrict the overall performance of the digital hydraulic system. Most of the current studies focus on the optimization on the dynamic characteristics or the energy characteristics, few studies have comprehensively considered the two characteristics of the valve together. In this paper, a pre-existing control algorithm (PECA) is proposed to improve the dynamic characteristics of the HSV, and simultaneously optimize the power losses of the HSV to improve its energy conversion efficiency. The results show that, compared with the traditional single-voltage driven strategy, the opening time of the PECA decreases by 29.4%, the closing time decreases by 59.6%, and the energy conversion rate increases by 7.9%. Full article

(This article belongs to the Special Issue New Challenges in Electrohydraulic Control System and Energy Saving)

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Review

Jump to: Research

15 pages, 2272 KiB

Open AccessReview

Review on Research Progress of Hydraulic Powered Soft Actuators

by Hu Shi, Kun Tan, Boyang Zhang and Wenqiao Liu

Energies 2022, 15(23), 9048; https://0-doi-org.brum.beds.ac.uk/10.3390/en15239048 - 29 Nov 2022

Cited by 1 | Viewed by 1809

Abstract

Soft actuators have received extensive attention in robotics and smart device applications due to their distinctive dexterity and compliance. Among them, hydraulic soft actuators play an important role in the area because they have much higher specific power and power density than other types such as pneumatic soft actuators. Nevertheless, the deformation of flexible materials in soft actuators brings about inherent hysteresis and nonlinearity, which severely hinders them from producing the desired movement in the presence of advanced control strategies. In this paper, previous research efforts made to enhance the driving capability and actuation efficiency of hydraulic soft actuators are illustrated and analyzed from the three aspects of architecture, materials, and control strategy. Meanwhile, the issues and challenges that have emerged when developing hydraulic soft actuators are discussed. Finally, the potential future development of hydraulic powered soft actuators is discussed. Full article

(This article belongs to the Special Issue New Challenges in Electrohydraulic Control System and Energy Saving)

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