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Georgia Institute of Technology | Marquette University | Milwaukee School of Engineering | North Carolina A&T State University | Purdue University | University of California, Merced | University of Illinois, Urbana-Champaign | University of Minnesota | Vanderbilt University
Fluid Power Innovation & Research ConferenceMinneapolis, MN | October 10 - 12, 2016
Four-Quadrant Multi-Fluid Pump/Motor
John Lumkes, PhDPurdue University
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FPIRC16 2
Project Overview / Title Major Objectives/Deliverables
Next Steps
• What are your research goals?• Design, Simulate, and Evaluate the
Feasibility of Mechanically Actuated Multi-fluid Pump/Motors
• How does this project fit into the CCEFP’s overall research strategy?
• Efficiency, Effectiveness, Environment • What is the original contribution of this
project?• Novel mechanical control of digital
pump/motors• What is the competing research or
methods? Why / what makes this technology better than the competition? What has been done in the past?
• Improvement of conventional units, other digital pump/motors (DPM)
• Efficiency, Controllability, Fluids• Electrical valve control for DPM
• What is planned for the next six months to one year?
• Develop the simulation and analyze test data for pump prototype
• How can industry help / contribute? • Component support/sponsorship
• Analyze test results from mechanically actuated pump
• Modify current digital pump/motor model and validate model using pump
• Simulate and design mechanical control four-quadrant pump/motor
• Experimentally test
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FPIRC16 3
MotivationMotivation
• In the United States– 2-3% of the energy transferred by fluid power– More than $50B/year, 7-8% of total CO2– Mobile systems average 22% in efficiency
• Pump improvement impacts systems– Pumps are ubiquitous in fluid power systems– Max system efficiency ~ pump efficiency– Smarter systems and configurations require better
pumps to maximize effectiveness
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FPIRC16 4
Research Outline
Cam Types
Valve Configuration
Implementation
Valve Improvement (Testing valves and incorporating 1E.6)
Control Algorithms(Mode Switching and Valve Timing)
Sensor Reduction
Four-QuadrantMulti-Fluid Pump/Motor
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FPIRC16 5
AdvantagesAdvantages
• Advantages over state-of-the-art units◦ Eliminate valve plate losses◦ Leakage scales closely with
displacement◦ Pumping of non-conventional fluids
(water)
• Advantages over other digital units in literature
◦ On/Off valves can open against high pressure Freedom in operating strategies Four quadrant operation
◦ Self starting in motoring Digital displacement control
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FPIRC16 6
AdvantagesDisadvantages
• Disadvantages(Electrically Actuated Valves)
◦ Additional electrical power consumption for valves
◦ Flow area of valves is less than traditional port plates
◦ Valve timing is critical for efficiency◦ Requires additional sensors and
embedded controls
Digital displacement control
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FPIRC16 7
Operating Strategies
Digital displacement control
◦ Flow Diverting Excess flow taken into the
chamber is diverted back to the low pressure port
◦ Flow Limiting Amount of flow taken into the
chamber is limited to the desired flow
◦ Sequential (Diverting or Limiting)
Individual cylinders are operated at full or zero displacement
4
20 BarInlet
320 BarOutlet
Valve 1 Valve 2
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FPIRC16 8
Operating Strategies
Digital displacement control
◦ Flow Diverting Excess flow taken into the
chamber is diverted back to the low pressure port
◦ Flow Limiting Amount of flow taken into the
chamber is limited to the desired flow
◦ Sequential (Diverting or Limiting)
Individual cylinders are operated at full or zero displacement
4
20 BarInlet
320 BarOutlet
Valve 1 Valve 2
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FPIRC16 9
Simulation Model• Matlab Simscape
– Physics Based Modeling
• Piston, cylinder, valve– Includes compressibility– Considers effect of valve losses– Considers leakage between piston
and cylinder– Includes valve throttling losses– Includes valve electrical
consumption
Simulation Model
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FPIRC16 10
Simulation Model
Simulation Results
Errors in valve delay, 1ms transition Effect of valve transition, 1ms delay
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FPIRC16 11
Experimental Test StandMulti-piston digital pump/motor test stand
• 3-piston digital pump/motor
• Two on/off valves per piston
• Three 2,000 Hz pressure transducers
• Check valve
• Two accumulators
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FPIRC16 12
Research Outline
Cam Types
Valve Configuration
Implementation
Valve Improvement (Testing valves and incorporating 1E.6)
Control Algorithms(Mode Switching and Valve Timing)
Sensor Reduction
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FPIRC16 13
Operating Strategy State Analysis
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FPIRC16 14
Mechanically Actuated Valves(MAV)
Advantages of cam driven valves:o Fast actuationo Consistento No electrical energy neededo Less complex controls and data
acquisitiono Most spring energy will be
recovered in closing
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FPIRC16 15
Cam Types
Simulation
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FPIRC16 16
Cam TypesSimulation Key Variables
Compression Angle: amount of shaft rotation needed to decompress the fluid
Transition Angle: amount of degrees to transition from closed to open valve state or vice versa
o Affects cam pressure angle
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FPIRC16 17
Cam ProfilesSimulation Results
1000
psi
2000
psi
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FPIRC16 18
Cam Phasing
Planetary
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FPIRC16 19
ImplementationRadial Piston Pump
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FPIRC16 20
Implementation
Inline Piston Pump
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FPIRC16 21
Prototype (+video)
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FPIRC16 22
• Prototype Pump Mechanism ready to test on existing digital pump/motor test stand
• Simulation study continuing (PumpLinx)• Next steps flow out of this intersection of test
data and simulation study
Summary