Browse Topic: Hydraulic control

Items (192)
Automotive Engineering: June 202626AUTP066/4/2026
New York 2026: diversity on full display New powertrain choices keep popping up on new vehicles from OEMs that debuted at NYIAS this year. Sealing integrity in a Formula 1 limited-slip differential High-temperature hydraulic control in a Formula 1 drivetrain requires dimensional stability, controlled sealing force, and resistance to wear under sustained pressure cycling. Inside the limited-slip differential, the sealing architecture plays a defined mechanical role in maintaining consistent torque management under race conditions. From ADAS to autonomy How engineering thermoplastics can advance sensor-based technologies. Synthetic data and the future of ADAS validation Why ADAS validation can't be solved with more miles alone. Intelligent power distribution will change the way vehicles are designed Electronic fuse (eFuse) technology can create electronic power distribution modules (ePDMs) for architectural flexibility, higher reliability, greater safety, and proactive maintenance. Editorial Maybe more than ever, let's talk transportation diversity The Navigator Can legacy automakers finally succeed with SDVs? AI scares and excites cybersecurity professionals at WCX Expert claims war hurting China's already-struggling economy NHTSA open to negotiated rulemaking on some safety issues Resilient propulsion strategies require options Driven: Honda Fastport eQuad Prototype Product Briefs Spotlight: Connectors & harnesses, EV thermal management Q&A Neural Concept's Thomas von Tschammer: Working with AI at speed
High-temperature hydraulic control in a Formula 1 drivetrain requires dimensional stability, controlled sealing force, and resistance to wear under sustained pressure cycling. Inside the limited-slip differential, the sealing architecture plays a defined mechanical role in maintaining consistent torque management under race conditions. In Formula 1, drivetrain reliability and performance are closely linked. The limited-slip differential (LSD) governs torque distribution between the rear wheels, allowing controlled transfer of power to the wheel with greater available grip. By limiting speed difference across the rear axle, the differential contributes directly to traction and cornering behavior, particularly where grip levels vary across the vehicle. At the center of this assembly is a hydraulic actuator that clamps a friction clutch inside the differential. The actuator modulates clutch engagement to redirect torque as grip levels change through corner entry, mid-corner load transfer, and acceleration on exit. Its performance depends on precise hydraulic control, which in turn depends on sealing integrity. Within this system, seal integrity is paramount, as significant leakage could cause a catastrophic loss of system function and force the team to retire the car.
Clarke, Andrew
With current and future regulations continuing to drive reductions in carbon dioxide equivalent (CO2e) emissions in the on-road industry, the off-road industry is also likely to be regulated for fuel and CO2e savings. This work focuses on converting a heavy-duty off-road material handler from a conventional diesel powertrain to a plug-in series hybrid, achieving a 49% fuel reduction and 29% CO2e reduction via simulation. Control strategies were refined for energy savings, including a regenerative braking strategy to increase regenerative braking and a load-following hydraulic strategy to decrease electrical energy consumption. The load-following hydraulic control shuts off the hydraulic electric machine when it is not needed—an approach not previously seen in a load-sensing, pressure-compensated system. These strategies achieved a 24.1% fuel savings, resulting in total savings of 61% in fuel and 41% in CO2e in the plug-in series compared to the conventional machine. Beyond control strategies, this study evaluated battery chemistry and charging strategy refinements for total cost of ownership (TCO) and lifetime CO2e. LFP batteries emerged as the most cost-effective and least emitting due to their longer lifespan, which reduced replacement frequency. Charging comparisons showed that Level 2 charging (L2C) typically resulted in lower TCO but higher lifetime CO2e than DC fast charging (DCFC). DCFC costs were heavily influenced by local demand charges, and DCFC emissions were heavily influenced by local grid emissions.
Goodenough, BryantCzarnecki, AlexanderRobinette, DarrellWorm, JeremySubert, DavidKiefer, DylanHeath, MatthewBrunet, BobKisul, RobertLatendresse, PhilWestman, JohnBlack, Andrew
The Tractor is essential in both agriculture and construction, equipped with a variety of implements for different operational conditions. Its hydraulic system is crucial for controlling these implements during fieldwork and transport. The quadrant assembly is a key part of the tractor’s hydraulic control system, allowing the operator to manage important functions. This includes hydraulic control and draft control, enabling the farmer or operator to use the PC and DC levers to adjust the movement of implements during various tasks. Tractors are commonly used in fields and farms where the soil can be loose and muddy, particularly during wet puddling operations. In these muddy conditions, tractors can accumulate mud in critical components, such as the quadrant assembly. This can lead to functional issues, increased friction, and problems within the hydraulic system, especially affecting the controls for hydraulics and lever shifting for implement handling. As a result, operators may need to exert more manual effort to operate the lever due to the added frictional forces. This paper addresses the challenges encountered with the current quadrant design and presents an innovative solution to resolve these issues. The existing quadrant assembly consists of a PC tube and DC shaft mounted on the same axis, while the proposed design utilizes a tandem or split shaft arrangement. This new configuration minimizes relative motion between moving linkage parts and facilitates easier maintenance access. Virtual simulations using CAE tools were conducted to validate the new design’s components, and multiple design iterations were performed to meet durability standards. Ultimately, the final innovative tandem quadrant assembly design has been filed for an Indian patent grant. This approach can be applied to all tractor quadrant assemblies to achieve optimal designs that reduce manual effort and improve the system’s mechanical advantage.
K, BheshmaPhadtare, YogeshGomes, MaxsonV, Ashok KumarPerumal, SolairajMagendran, G
DHT hybrid transmission assembly control system discussed in this paper includes hydraulic control, hybrid mode switching control, shift control, dual motor control, clutch and motor thermal management. The hybrid mode is divided into four modes: the EV mode, the serial mode, the parallel mode and the launch mode. Hydraulic control includes torque-pressure conversion, clutch pressure kiss point adaption, clutch oil filling time adaption. Shift control includes shift type decision, shift sequence control, shift inertia process based on motor intervention. Thermal management includes clutch flow and motor flow distribution. Motor control include the current control, mode control and boost strategy of permanent magnet synchronous motor in dual hybrid system, which has good stability and robustness. Motor mode includes initialization mode, normal mode, fault mode, active discharge mode, power off mode. The boost strategy of the hybrid system is based on boost mode management, boost target voltage determination and boost PI control. Finally, the real vehicle test is carried out to verify the effectiveness and advancement of the DHT control design.
Jing, JunchaoZhang, JunzhiLiu, YiqiangWang, ZhentaoXue, Tianjian
Tractor is primarily used for Haulage and agricultural applications due to this high tractive effort. A tractor usage has been increased in recent times for its wide range of implement applications. Considering environmental factors and sustainability, restrictions are set on the Tractor emissions. This brings new challenge in the Tractor industry to reduce the carbon footprint. Conventional casting process involves preparation of die & mold, material removal and machining in the final stage to get the desired final product. Alternatively Additive Manufacturing Process (AMP) helps in creation of lighter and stronger parts by adding material layer by layer. By saving the material, weight of the overall Tractor is reduced which helps in reducing carbon footprint. But the disadvantage of this process is the limited availability and high cost of AMP material and lack of infrastructure/skill set for operation handling. With the learnings of Additive Designs, generated many concepts with a new methodology which we call Additive Inspired Design. This Methodology has given very high level of design optimization even with conventional manufacturing processes. Develop designs without any boundaries (i.e., Additive approach) to achieve maximum optimization. Further reverse modifies the design to suit conventional manufacturing process thereby still achieving high level of optimization. In this paper, present work discusses about virtual validation process for components developed using Inspired additive designs along with physical validation in lab. To predict the operational loads acting on hydraulic system from Real world Usage pattern (RWUP) performed MBD analysis to extract the load on different hitch points of the Hydraulic control valve system. Static Non-Linear analysis was performed on multiple design Iterations to meet the durability criteria. Finalized Inspired Control valve assembly is successfully tested in lab and implemented successfully. With the help of inspired design, 37 tons of C02 emissions annually (220 Trees) is eliminated by achieving 128 tons raw material savings. Same approach can be deployed to all Tractor components to achieve Optimum designs to reduce the carbon footprint further.
Dumpa, Mahendra ReddyPerumal, SolairajK, BheshmaGomes, MaxsonMagendran, GRedkar, DineshLondhe, Abhijit
In recent days the usage of Electro - Hydraulic Control Unit (EHCU) is increased acutely in light passenger vehicle applications apart from the passenger cars. The main advantage of using electro - Hydraulic control unit (EHCU) is operational flexibility, consistent performance customization, increase durability and lower running cost. During running, the mechanical load is converted into the electronic signal by using transmitter. The electronic devices are highly responsive when compared with mechanical devices, so, it is necessary to reduce the Noise, Vibration and Harshness (NVH) in the system. As per the recent trend, the NVH pollution should be as low as possible in the vehicle. It is necessary to maintain the NVH in minimum level in the electronic device to meet the overall performance of the system. The vibrational isolator is one of the key components used in Electro – Hydraulic Control Unit to reduce the noise and vibration implication of the system. The process of using vibration isolator with hyper-elastic material is highly nonlinear dynamic and complex in nature. It acts as an insulation between EHCU and external system. In this study, vibration characteristics of the EHCU is determined using Finite Element Analysis (FEA) considering rubber isolator which is made up of hyper-elastic material. In this study there are two damping factors like material damping and structural damping are considered to predict the vibrational behavior of the system. Also, the results are compared with lab validation test results and the damping factors are standardized for future reference.
Govindarasu, AnbarasuT, Dr.SukumarSubramanian, Vivek
This SAE Aerospace Information Report presents the following factors that affect hydraulic pump life and performance: a The need to supply hydraulic fluid at the correct pressure and quality to the pump inlet port b Considerations for the pump output c Factors to be considered for the pump case drain lines d The mounting of the hydraulic pump e Hydraulic fluid properties, including cleanliness
A-6C4 Power Sources Committee
This SAE Standard includes only those towing winches commonly used on skidders and crawler tractors. These winches are used on self-propelled machines described in SAE J1057, J1116, and J1209. Specifically excluded are those winches used for hoisting operations.
MTC4, Forestry and Logging Equipment
Dual Clutch Automatic Transmission (DCT) has the characteristics of light weight, fast shift speed and high transmission efficiency. Electric vehicles equipped with dual clutch transmission can effectively improve vehicle power performance and economy. Electro-hydraulic control system, as a key component of transmission, determines the quality of shift. In this paper, an electro - hydraulic control system is designed based on two - speed dry dual clutch transmission of electric vehicle. Firstly, the hydraulic components of the system were selected and calculated based on the vehicle parameters. Secondly, the electro-hydraulic control system of the dual clutch transmission was established according to the transmission control strategy and the matching hydraulic valve body assembly was designed. Then, the key components of the system were simulated to analyze their dynamic shift characteristics and response characteristics. Finally, through various tests, it is verified that the designed electro-hydraulic control system and transmission meet the design requirements. The results show that the electro-hydraulic control system can meet its working characteristics and shift requirements.
Zhang, ZeChen, YongLi, GuangxinTan, YanjunLin, XiaozheWang, Yougang
AE-8C2 Terminating Devices and Tooling Committee
The data in this document is, at this stage, primarily concerned with the interface of pallet/container loaders and lower-deck compartments of standard and wide-body aircraft although the principles illustrated may be applied to the main-decks of narrow and wide-body aircraft. NOTE: For the purpose of this document, in accordance with Part 3 of the Directives for the technical work of ISO and with accepted IATA practice, minimum essential criteria defined by the word "shall" are absolute requirements. Recommended criteria identified by the word "should", while considered important, are not mandatory.
AGE-3 Aircraft Ground Support Equipment Committee
In order to meet upcoming emission targets, an increasing number of ships using Liquefied Natural Gas (LNG) as fuel have been put into service. In this context, many shipowners are particularly interested in the dual-fuel (DF) large-engine technology, which enables ships to operate with both gaseous and conventional liquid fuels. The use of different combustion principles in DF engines requires a layout of the base engine with a relatively low compression ratio (CR) for the gas mode to prevent unstable combustion (knocking). However, this layout leads to disadvantages in the Diesel operation mode, which requires a higher CR for optimal fuel efficiency. Therefore, a two-stage variable compression ratio (VCR) system is a technology particularly suitable for DF engines. It allows to reduce fuel costs by approximately 5.5%. This article presents an innovative VCR connecting rod (conrod) design for modern DF engines that adapts the piston position by changing the effective conrod length. The VCR system is developed by the Institute for Combustion Engines of the Rheinisch-Westfälische Technische Hochschule (RWTH) Aachen University together with Forschungsgesellschaft für Energietechnik und Verbrennungsmotoren (FEV) Europe GmbH. It is equipped with a novel functional principle inside the conrod’s small eye specifically tailored to large engine boundary conditions. The system includes an advanced hydraulic circuit combining the function of a hydraulic freewheel, the oil supply for piston cooling, and a mechanical locking device (LD) for both CRs. In a comprehensive simulation study, the layout and the system behavior of the new hydraulic circuit are presented using a one-dimensional (1D) hydraulic-mechanical simulation model, which was validated in advance with measurement data from a passenger car (PC) engine. The study intends to examine the functional behavior of the VCR system during engine operation. The focus is on the switching process between the two CRs, as well as on the fixed CR operation. The aim is to provide a deeper understanding of the hydraulic-mechanical behavior and to identify special requirements on the system.
Marten, ChristopherPendovski, DenisPischinger, StefanBick, Werner
With the development of intelligent and electric vehicles, higher requirements are put forward for the active braking and regenerative braking ability of the braking system. The traditional braking system equipped with vacuum booster has difficulty meeting the demand, therefore it has gradually been replaced by the integrated braking system. In this paper, a novel Integrated Braking System (IBS) is presented, which mainly contains a pedal feel simulator, a permanent magnet synchronous motor (PMSM), a series of transmission mechanisms, and the hydraulic control unit. As an integrative system of mechanics-electronics-hydraulics, the IBS has complex nonlinear characteristics, which challenge the accurate pressure control. Furthermore, it is a completely decoupled braking system, the pedal force doesn’t participate in pressure-building, so it is necessary to precisely identify driver’s braking intention. To improve the control accuracy of the system, this paper proposed a novel pressure control strategy based on driver braking intention identification. Firstly, the structure and working principle of the novel integrated braking system was introduced. Secondly, the driver's braking intention identification strategy was designed. Thirdly, Considering the nonlinear and dynamic characteristics of the system, a cascade closed-loop control strategy including a pressure loop by the feedforward-feedback method, a position loop by the sliding-mode control method, and current loop with friction compensation was proposed. Finally, based on dSPACE products, a hardware-in-the-loop (HiL) experimental bench was built for algorithm verification. The HiL experiment results show that the pressure control strategy has the advantages of accurate response, the braking system pressure follows the driver's expected pressure well.
Zhu, BingZhang, YihanZhao, JianChen, ZhichengJin, Wanli
The RADIALcvt is a traction drive continuously variable transmission (CVT) implemented in a new novel radial configuration mechanical assembly. The RADIALcvt functions as a multi-parallel power path (at least six) type of CVT, which consists of only one steel-on-steel, line contact, traction drive interface in each power path. A constant input radius on the traction drive input makes it possible to use a constant clamping force, which is provided by mechanical springs, thus eliminating the need for a hydraulic control system. The RADIALcvt has a very large radius variation on the traction drive output, which provides the ratio variation. The test and simulation results of the first RADIALcvt prototype was published in [1] and presented mechanical efficiencies above 90%. This article presents the simulation and test results of the second-generation RADIALcvt prototype, which presents mechanical efficiencies above 94% and includes measured parameters of mechanical efficiency, slip, traction curves, and ratio torque at different loads while providing excellent partial load versus mechanical efficiency properties. A methodology for predicting the efficiency map using the no load torque loss is also proposed.
Naude, JanGoodrich, Raymond
This study aims to solve the problem of impact in a parallel hybrid electric system based on the continuously variable transmission (CVT) during switching from pure electric mode to engine-driven, power-generating mode. Taking into account the torque response characteristics of the engine and motor and the dynamic characteristics of the wet clutch hydraulic control system, the mode switching process is divided into six stages, namely, pure electric mode, wet-clutch free travel, engine start-up, engine speed synchronization, clutch combination, and engine intervention drive. A coordination control strategy is developed based on the model predictive control algorithm to ensure smooth mode switching. The effectiveness of the control algorithm is verified using Matlab/Simulink and the AMESim co-simulation platform. Results show that with the mode switching coordination control strategy, the components of the system work harmoniously. The maximum impact is reduced by 52.0% at the speed synchronization stage and by 84.3% at the clutch coupling stage compared with the uncoordinated control situation.
Zeng, XiaohuaLi, XiaojianDong, Bingbing
The Electromechanical Brake Booster system (EMBB) integrates active braking and energy recovery and becomes a novel brake-by-wire solution that substitutes the vacuum booster. While the intelligent unmanned vehicle is in unstable state, the EMBB can improve the vehicle yaw stability more quickly and safely. In this paper, a new type of integrated EMBB has been designed, which mainly includes two parts: servo motor unit and hydraulic control unit. Aiming at the dynamic instability problem of intelligent unmanned vehicle, a three-layer vehicle yaw stability control structure including decision layer, distribution layer and execution layer is proposed based on integrated EMBB. Firstly, the decision layer calculates the ideal yaw rate and the side slip angle of the vehicle with the classic 2DOF vehicle dynamics model. The boundary of the stable region is determined by the phase plane method and the additional yaw moment is determined by the feedback PI control algorithm. Secondly, the distribution layer optimally selects the wheel with the highest differential braking efficiency and assigns the brake pressure to the corresponding wheel based on the additional yaw moment calculated by the decision layer. In the execution layer, the servo motor unit employs the position-current double closed-loop PI algorithm to achieve rapid building-up pressure and then precise control of the single-wheel pressure is achieved by controlling the electromagnetic valve of the hydraulic unit. Finally, with the dSPACE products, we built the hardware-in-the-loop (HIL) test bench based on integrated EMBB. The proposed control strategy is verified by using Similator to run CarSim in real-time and MicroAutoBox to run the algorithm. The HIL experiment results show that the yaw stability control algorithm based on integrated EMBB can effectively restore the unstable vehicle to the stable driving zone and enhance the driving safety of the complete vehicle.
Lao, DexingWu, JianHe, RuiZhu, BingZhao, JianChen, Zhicheng
The latest trend in transmission hydraulic controls development ise body integrated direct acting control solenoid, ted by multiple automotive OEMs. The advantages of integrated direct acting control solenoids are key enablers for OEMs to meet more and more stringent fuel economy requirement and competitive environment. In the meantime, there are unique challenges in both designing and manufacturing of such solenoids, due to the fact the solenoid armature can only push the spool valve with limited force and limited stroke. Through analytical methods, this paper explains design guidelines to overcome the challenges and quantifies the impact of design decision to critical functional objectives. Multiple valve design configurations, including both normally low and normally high functionality, are covered in the analysis. Unique manufacturing process concerns are also addressed.
Xie, Zhe
The electro-mechanical brake booster (EMBB) and hydraulic control unit (HCU) constitute the electro-mechanical brake system, which can meet the requirements of brake system for intelligent vehicles. It does not need vacuum source, provides active braking function, have high control accuracy and fast response. But it has two electronic control units (ECU), which need coordinated control. When ABS is triggered, the pressure of the master cylinder keeps rising and falling, and the pressure fluctuates greatly. This will lead to noise and reduce the durability of the system. In this paper, a pressure optimization control strategy under ABS condition is proposed. Firstly, the structure and control strategy of EMBB are introduced. Secondly, the braking characteristics without pressure optimization control are analyzed. Thirdly, based on the demand of maximum cylinder pressure, a three-closed-loop pressure optimization control strategy is established. Finally, based on the Hardware-In-the-Loop platform, the control strategy is verified. HIL test shows that the strategy can effectively reduce the pressure fluctuation of the master cylinder when triggered by ABS, while ensuring the control performance of ABS.
Wang, JingtianWu, JianHe, RuiChen, Zhicheng
SAE J1939-2 specifies the requirements for application of SAE J1939 in agricultural and forestry equipment. This document specifies the series of documents within the set of SAE J1939 documents that are applicable to agricultural and forestry equipment and provides further requirements for this industry. The SAE and ISO groups have cooperated to define agricultural and forestry networks in a manner to allow compatibility of ECUs and messaging protocols between the A&F and the T&B networks.
Truck and Bus Control and Communications Network Committee
In the process of ABS control, the Anti-lock braking system (ABS) of the vehicle adjusts the wheel cylinder brake pressure through the hydraulic actuator so as to control the movement of the wheel. The high-speed on-off valve (HSV) is the key components of the Anti-lock braking system. HSV affects the performance of the hydraulic actuator and the valve response characteristics affects the Anti-lock braking system pressure response as well as braking effect. In this paper, the electromagnetic field theory and flow field theory of HSV are analyzed, and simulation analysis of electromagnetic field characteristics of HSV is done by ANSYS. Combined with the ANSYS analysis results, a precise physical model of HSV is constructed in AMESim. Meanwhile, the valve response characteristics are analyzed. Moreover, the influence of different wheel cylinder diameter and PWM carrier frequency on hydraulic braking force characteristics are analyzed. The open-loop control methods of hydraulic braking force based on Look-up tables and T-S fuzzy structure are comparatively analyzed. The results show that T-S fuzzy controller can be more direct and rapid training to obtain buck-boost surface without fitting and interpolation of data surface, it is more adaptable. The single-wheel model and ABS sliding mode control module are established in Simulink. The inner ring of the module is hydraulic brake force controller, it is used to control hydraulic braking force precisely. The outer ring of the module is a sliding mode controller to control the wheel slip rate. Based on the above two open-loop control strategies, ABS control can be better achieved to realize anti-lock control of the vehicle in the emergency braking conditions.
Zhuo, GuirongShen, HuadongXue, RuonanWu, Shenchen
This SAE Aerospace Information Report (AIR) provides design information of various contemporary aircraft fly-by-wire (FBW) flight control actuation systems that may be useful in the design of future systems for similar applications. It is primarily applicable to manned aircraft. It presents the basic characteristics, hardware descriptions, redundancy concepts, functional schematics, and discussions of the servo controls, failure monitoring, and fault tolerance. All existing FBW actuation systems are not described herein; however, those most representing the latest designs are included. While this AIR is intended as a reference source of information for aircraft actuation system designs, the exclusion or omission of any other appropriate actuation system or subsystem should not limit consideration of their use on future aircraft.
A-6A3 Flight Control and Vehicle Management Systems Cmt
An investigation was completed into the power loss associated with a rotating feed-through (RFT) design feature used to transfer lubrication and a hydraulic control signal from the static reference frame to a rotating reference frame in the NASA GRC two-speed transmission tests conducted in the Variable-Speed Drive Test Rig. The RFT feature, not commercially available, was created specifically for this research project and is integral to all two-speed transmission configurations tested, as well as a variant concept design for a geared variable-speed transmission presented at AHS Forum 71 in 2015. The experimental set-up and results from measurements in the isolated rotating-feed-through (RFT) experiments are presented. Results were used in an overall power loss assessment for a scaled conceptual 1,000 horsepower inline concentric two-speed transmission to support a NASA Revolutionary Vertical Lift Technologies (RVLT) Technical Challenge, demonstrating 50% speed change with less than 2% power loss while maintaining current power-to-weight ratios.
Stevens, MarkValco, MarkLaBerge, Kelsen
As a novel assist actuator of brake system, the electromechanical brake (EMB) booster has played a significant role in the battery electric vehicles and automatic driving vehicles. It has advantages of independent to vacuum source, active braking, and tuning pedal feeling compared with conventional vacuum brake booster. In this article, a novel EMB booster system is proposed, which is consisted of a permanent magnet synchronous motor (PMSM), a two-stage reduction by gears and ball screw, a servo body, and a reaction disk. Together with the hydraulic control unit, it has two working modes: active braking for automatic drive and passive braking for driver intervention. The structure and work principle of the electric brake booster system is first introduced. The precise control from pedal force to hydraulic pressure is the key for such a power-assisted brake actuator. We translate the control problem of force feedback control to position tracking control. Then, a nonlinear control method for power-assisted braking is presented, which could be divided into three parts: (i) signal processing and driver’s braking behavior recognition, (ii) obtaining target position, and (iii) precise position controlling of PMSM. For this, a Kalman filter was designed to do the signal processing firstly. Next, the method of logic threshold is applied to recognize the driver’s braking behavior. At last, the position control of PMSM is achieved by a triple-closed-loop proportional-integral-derivative (PID) controller with the technology of friction compensation and tuning gain. The contrast tests between the electric brake booster and the vacuum brake booster are implemented based on RCP test environment to verify the validity and effectiveness of the mechanism and controller. The wheel cylinder pressure precise control tests in active braking mode are designed and implemented. Test results show that the performance of the EMB booster system behaves well.
Chen, PengchengWu, JianZhao, JianHe, RuiLiu, HaizhenYang, Changhai
In this paper, an integrated electronic hydraulic brake(I-EHB) system is introduced, which is mainly composed of a motor, a worm gear, a worm, a gear, a rack etc. The friction leads the system to the creeping phenomenon and the dead zone. These phenomenon seriously affect the response speed and the hydraulic pressure control .In order to realize the accurate hydraulic pressure control of I-EHB system, a new friction compensation control method is proposed based on LuGre dynamic friction model. And the theoretical design of adaptive control method is designed based on the feedback of the master cylinder pressure and the operating state of the system. Then the stability of the control method is proved by Lyapunov theorem. A co-simulation model is built with Matlab/Simulink and AMESim, so as to prove the validity of the control method. Related experiments are carried out to track the different target signals, which is step signal, (different amplitude and frequency) sine wave signal and Artemis signal. Compared with the test result with PID control method or compensation control method based on static friction model, this method based on LuGre dynamic friction model has a definite improvement, which has advantages in dynamic control error. The maximum dynamic control error at low frequency with this method is less than 1 bar and the RMS of error is about 0.2 bar. Therefore this method is an effective way to control the I-EHB system.
Li, HaochengYu, ZhuopingXiong, LuHan, Wei
A general principle scheme of IEHB (Integrated Electro-Hydraulic Brake system) is proposed, and the working principle of the system is simply introduced in this paper. Considering the structure characteristics of the hydraulic control unit of the system, a kind of time-sharing control strategy is adopted to realize the purpose of independent and precise hydraulic pressure regulation of each wheel brake cylinder in various brake conditions of a vehicle. Because of the strong nonlinear and time varying characteristics of the dynamic brake pressure regulation processes of IEHB, its comprehensive brake performance is mainly affected by temperature, humidity, load change, the structure and control parameters of IEHB, and so on. Under certain temperature, humidity and load conditions, whether the matching of the structure and the control parameters of IEHB is appropriate or not, the brake performance of a vehicle would be affected directly and severely, and then the safe driving of a vehicle could not be guaranteed effectively. In order to enhance the adaptability of the pressure regulating performance of IEHB to external influence factors and improve the comprehensive performance index of IEHB, using the software and hardware test platform of IEHB, combining the robustness optimization design method based on the application of GA (Genetic Algorithm) and modern generalized experiments, the structure and the control parameters of IEHB are matched and optimized. Finally, by comparing the results before and after optimization, it is verified that the pressure regulation of optimized IEHB is more rapid, more accurate and more robust, the comprehensive brake performance is significantly improved, and the new type of brake system could well meet the application requirements of an advanced vehicle chassis control system in the future.
Yang, XiongLi, JingMiao, HuiShi, Zheng Tang
This SAE Standard includes only those towing winches commonly used on skidders and crawler tractors. These winches are used on self-propelled machines described in SAE J1057, J1116, and J1209. Specifically excluded are those winches used for hoisting operations.
MTC4, Forestry and Logging Equipment
This recommended practice provides a method, test set-up, and test conditions for brake hydraulic component flow rate measurement for high differential pressure (>5 bar) flow conditions. It is intended for hydraulic brake components which affect the brake fluid flow characteristics in a hydraulic brake circuit, that are part of a circuit for which the flow characteristics are important to system operation, and that are exposed to high operating pressure differentials (in the 5 to 100 bar range). Typical applications may include measurement of flow through chassis controls valve bodies, orifices in the brake system such as in flow bolts, junction blocks, and master cylinders, and through brake pipe configurations.
Hydraulic Brake Components Standards Committee
A vehicle dynamics stability control system based on integrated-electro-hydraulic brake (I-EHB) system with hierarchical control architecture and nonlinear control method is designed to improve the vehicle dynamics stability under extreme conditions in this paper. The I-EHB system is a novel brake-by-wire system, and is suitable to the development demands of intelligent vehicle technology and new energy vehicle technology. Four inlet valves and four outlet valves are added to the layout of a conventional four-channel hydraulic control unit. A permanent-magnet synchronous motor (PMSM) provides a stabilized high-pressure source in the master cylinder, and the four-channel hydraulic control unit ensures that the pressures in each wheel cylinder can be modulated separately at a high precision. Besides, the functions of Anti-lock Braking System, Traction Control System and Regenerative Braking System, Autonomous Emergency Braking can be integrated in this brake-by-wire system. A sliding mode variable structure vehicle dynamics stability controller based on hierarchical control framework is built in MATLAB/Simulink. The I-EHB actuator model and vehicle dynamic model with 15 degrees of freedom are built in simulation package AMESim through a parameterized and modularized method. Simulations are conducted via co-simulation platform using MATLAB/Simulink and AMESim under scenarios of the typical braking and NHTSA FMVSS 126 standard-Sine With Dwell. Simulation results show that hydraulic braking forces are coordinated well during typical braking process, verifying the feasibility and effectiveness of the models built and the control strategy proposed. Under Sine With Dwell maneuver, compared with the base systems equipped without/with the conventional ESP, the proposed stability control system has a good improvement on the vehicle dynamics.
He, XiangkunYang, KaimingJi, XuewuLiu, YahuiDeng, Weiwen
Two control strategies, safety preferred control and master cylinder oscillation control, were designed for anti-lock braking on a novel integrated-electro-hydraulic braking system (I-EHB) which has only four solenoid valves in its innovative hydraulic control unit (HCU) instead of eight in a traditional one. The main idea of safety preferred control is to reduce the hydraulic pressure provided by the motor in the master cylinder whenever a wheel tends to be locking even if some of the other wheels may need more braking torque. In contrast, regarding master cylinder oscillation control, a sinusoidal signal is given to the motor making the hydraulic pressure in the master cylinder oscillate in certain frequency and amplitude. Hardware-in-the-loop simulations were conducted to verify the effectiveness of the two control strategies mentioned above and to evaluate them. The simulation platform consists of the I-EHB hardware and software including CarSim and MATLAB/Simulink as well as LabVIEW serving as the communication tool. Conclusions can be reached in the light of testing results that both control strategies were able to achieve anti-lock braking under emergency situations. Compared with safety preferred control, master cylinder oscillation control performed better on the functionality of avoiding braking lock and the reduction of braking distance. Also, it is capable of working with electronic stability control systems (ESC) while safety preferred control cannot.
Liu, TianyangYu, ZhuopingXiong, LuHAN, Wei
Fuel economy regulations have forced the automotive industry to implement transmissions with an increased number of gears and reduced parasitic losses. The objective of this research is to develop a high fidelity and a computationally efficient model of an automatic transmission, this model should be suitable for controller development purposes. The transmission under investigation features a combination of positive clutches (interlocking dog clutches) and conventional wet clutches. Simulation models for the torque converter, lock-up clutch, transmission gear train, interlocking dog clutches, wet clutches, hydraulic control valves and circuits were developed and integrated with a 1-D vehicle road load model. The integrated powertrain system model was calibrated using measurements from real-world driving conditions. Unknown model parameters, such as clutch pack clearances, compliances, hydraulic orifice diameters and clutch preloads were estimated and calibrated. Simulation results, such as vehicle acceleration, turbine speed, and output shaft speed, are reported and compared with the measured data to validate the transmission model. Subsequently, the transmission model was coupled with internal combustion engine and road load models. This arrangement permitted investigating the dog clutch engagement dynamics under transient conditions. The relative speed of the dog clutch halves was found to be highly sensitive to the transmission input torque, which indicates that a precise engine torque control schemes are necessary for successful engagement.
Alzuwayer, BasharPrucka, RobertHaque, ImtiazVenhovens, Paul
This Aerospace Recommended Practice provides general requirements for Electrohydrostatic Module (EHM) that is used in Electrohydrostatic Actuator (EHA) for aerospace applications. This document includes design, performance and test (production and qualification) requirements.
A-6B2 Electrohydrostatic Actuation Committee
Tractor hitch control system is used for attaching and operating various Agricultural Implements and for operating tipping trailer. The system has also got provision to attach additional Aux valves for rear and front mounted attachments. The rear mounted implements are coupled to the tractor using Three Point Linkage (3PL) System. The hitch hydraulics system consists of hydraulic pump, filter, piping’s, fittings and hydraulics lift unit. Hydraulics lift unit consists of a proportional control valve, cylinder, piston and power linkages. Conventional control valve is hydro mechanical part operated by mechanical linkages. The control valve and linkages plays major role in performance of hydraulics system. Hydraulics is required to operate in extreme conditions of soils such as very soft like sand to very hard like black cotton sand. These two extreme conditions makes linkage and control valve optimization work very challenging and very difficult to get single solution for soft and hard conditions. In addition to best performance requirements, lesser power loss and operating effort are also important for customer satisfaction. To meet this challenge of high on performance in all soil conditions, effortless operation, high on efficiency (less hydraulics power loss) and aesthetics, Electro Hydraulics Hitch is the best solution. In the present work, Electro Hydraulics Hitch System is designed and developed for Agricultural Tractor to replace conventional hydro mechanical hitch. This system consists of specially made control valve manifold using Solenoid Valves, Hydraulic Control Unit (HCU), Position Sensor, Draft Sensor (Load Cell) and input levers with sensors. They are connected by using suitable wiring harness. The system is having all features functions i.e. Position Control (PC), Draft Control (DC) and Quick Lift (QL) of conventional system. The basic common valves like, Pressure Relief Valve (PRV), Check Valve (CV), Shock Load relief Valve (SLRV), Isolator valve and Tipping trailer port are adopted from current design. The customer touch points are maintained same as that of conventional type i.e. PC, DC levers and QL button. The work also includes analysis and optimization using Simulink Matlab, performance tests in lab and fields for proving in various soil conditions.
Bhondave, BabuGanesan, TVarma, NaveenRenu, RajasekarSabarinath, N
The use of hybrid, fuel cell electric, and pure electric vehicles is on the increase as part of measures to help reduce exhaust gas emissions and to help resolve energy issues. These vehicles use regenerative-friction brake coordination technology, which requires a braking system that can accurately control the hydraulic brakes in response to small changes in regenerative braking. At the same time, the spread of collision avoidance support technology is progressing at a rapid pace along with a growing awareness of vehicle safety. This technology requires braking systems that can apply a large braking force in a short time. Although brake systems that have both accurate hydraulic control and large braking force have been developed in the past, simplification is required to promote further adoption. This paper describes the following three items: (1) an examination of the brake system functions that realize the regenerative-friction brake coordination and collision avoidance support functions, (2) considerations and a proposal for a brake system that achieves the functions described in item (1) with a simple structure, and (3) development of core technology for controlling the wheel cylinder pressure in a brake system equipped with a hydraulic regulator.
Okano, TakahiroSakai, AkiraKamiya, YusukeMasuda, YoshioYamaguchi, Tomoyuki
With the development of vehicle electrification, electronic hydraulic brake system is gradually applied. Many companies have introduced products related to integrated electronic hydraulic brake system (I-EHB). In this paper, an I-EHB system is introduced, which uses the motor to drive the reduction mechanism as a power source for braking. The reduction mechanism is composed of a turbine, a worm, a gear and a rack. A control method based on command feed-forward is proposed to improve the hydraulic pressure control of I-EHB. Based on previous research, we simplify the system to first order system, and the theoretical design of the command feed-forward compensator is carried out. The feed-forward controller is applied, including the velocity feed-forward and the acceleration feed-forward, to improve the response speed and tracking effect of the system. Then, related experiments were carried out on test bench to track three different types of target signal (different amplitude and frequency), step signal, sine wave signal and triangular wave signal. Compared with the test result of PID control method, the proposed method has the advantages of fast response and short regulation time. And the Control error at low frequency of the method is about 2 bar - reduced by 56% compared with PID control. Therefore, this method can effectively control the Hydraulic pressure of integrated electronic hydraulic brake system.
Huang, JieXiong, LuXu, SongyunYu, Zhuoping
With the electrification and intelligentialization of vehicle, requirements on more intelligent and integrated brake system are put forward. A novel integrated-electro-hydraulic brake system (I-EHB) for automotive is presented to fulfill these requirements. I-EHB is consisted of active power source (APS), pedal feel emulator (PFE), electro control unit (ECU) and hydraulic control unit (HCU). The system characteristics of I-EHB are tested through test rig. According to characteristics experiments, friction and non-linear phenomena in hydraulic pressure control are found. In order to overcome these phenomena in control of I-EHB, chatter-compensation is adopted based on experiment analysis. Algorithm are tested and optimized through test rig. As a result, through chatter-compensation the hydraulic pressure is controlled accurately and chatter-compensation is optimized for different working conditions.
Xu, SongyunYu, ZhuopingXiong, Lu
During the vehicle braking, the Regenerative braking system (RBS) transforms the kinetic energy into electric power, storing it in the power sources. To secure the baking process, it is required to use hydraulic braking pressure to coordinately compensate the regenerative braking pressure. The traditional hydraulic pressure control algorithm which is used in regenerative braking system coordinated control has obvious laddering effect in braking. Unit control cycle pressure deviations seriously affect the comfort and the braking feeling on the vehicle. In order to ensure the accurate implementation of the brake pressure on the wheel cylinder, according to the hardware configuration of regenerative braking system, this paper analyzes the active pressurization state of RBS during braking, acquires the overflow characteristics of the switch valve in ESP hydraulic control unit by designing of high frequency characteristic test experiment, the control range of valve core displacement in the state of inlet valve differential pressure balanced and the relationship between pressure growing rate and inlet valve control duty ratio under the different states of wheel cylinder pressure. On this basis, this paper finishes the development of algorithm of active pressurization control, building the hardware-in-loop testing platform. The test result shows that the actual wheel cylinder pressure can follow the aiming wheel cylinder well, the differential of wheel cylinder can be controlled in the range from −5Bar to 5Bar, the whole pressurization rate follows well compared with traditional control algorithm, justifies the feasibility of the active pressurization control algorithm through the virtual cycle.
Yang, YiChu, LiangYao, LiangGuo, Chong
High speed on-off valve is applied widely in vehicle control systems. When high speed on-off valve is controlled by Pulse Width Modulation (PWM) of high frequency, the valve core can float at a certain position which is adjusted by changing the duty ratio within a certain effective range. Then the high speed on-off valve can control the flow and pressure linearly like proportional valve. Thus it is essential to extend the effective range of duty ratio to improve the linear control performance of high speed on-off valve. In this paper, the high speed on-off valve of the automotive Electronic Stability Program (ESP) is the focus, and its flow force is analyzed in detail to get the effects of hydraulic parameters on the valve performance. The mathematic model of the high speed on-off valve is derived. Then the valve structural parameters are optimized according to the Genetic Algorithm(GA), offering the theoretical references for extending the effective duty ratio of PWM. Besides, the simulation model of high speed on-off valve is established in MATLAB/Simulink, and then embedded in the Hydraulic Control Unit (HCU) simulation model established in AMESim, resulting in the co-simulation model of hydraulic actuator. Finally the simulation model is verified by the hardware-in-loop tests. Based on theoretical analysis, simulations and tests, it is critical to increase the range of flow force for extending the effective range of duty ratio. The pressure difference, the valve seat angle and the throttle diameter of the high speed on-off valve have great effects on the flow force. At last the effects of structural parameters of the high speed on-off valve on extending the range of the linear control are proposed, serving as references for improving the linear control performance of high speed on-off valve.
Meng, AihongSong, Jian
The permanent-magnet DC motor, which is directly connected to the hydraulic pump, is a significant component of hydraulic control unit (HCU) in an anti-lock braking system (ABS). It drives the pump to dump the brake fluid from the low-pressure accumulator back to master cylinder and makes sure the pressure decreases of wheel cylinder in ABS control. Obviously, the motor should run fast enough to provide sufficient power and prevent the low-pressure accumulator from fully charging. However, the pump don't need always run at full speed for the consideration of energy conservation and noise reduction. Therefore, it is necessary to accurately regulate the speed of the DC motor in order to improve quality of ABS control. In this paper, an accurate speed control algorithm was developed for the permanent-magnet DC motor of the ABS to implement the performance of the system, reduce the noise and save the energy in the meanwhile. Firstly, the hydraulic brake system and the DC motor models of the ABS were established in the AMESim and Matlab/Simulink respectively, and the data exchange was realized through AMESim special interface module and MATLAB S function. Then, the co-simulation model was validated by the experiment data. Furthermore, an accurate speed control algorithm for DC motor was developed based on the charging state of the low-pressure accumulator, and a pulse width modulation (PWM) method was proposed to control the speed of DC motor. Finally, the proposed algorithm was simulated in the co-simulation platform to verify the decompression response speed of the wheel cylinder and the energy consumption of the DC motor. The results show that accurate speed control algorithm can effectively reduce the power consumption of the motor, at the same time ensure the performance of ABS control system.
Zhu, BingGong, JiapengZhao, JianWu, JianDeng, Weiwen
This SAE Aerospace Information Report (AIR) has been prepared to provide information regarding options for optical control of fluid power actuation devices. It is not intended to establish standards for optical fluid power control, but rather is intended to provide a baseline or foundation from which standards can be developed. It presents and discusses approaches for command and communication with the actuation device via electro-optic means. The development of standards will require industry wide participation and cooperation to ensure interface commonality, reliability, and early reduction to practice. To facilitate such participation, this document provides potential users of the technology a balanced consensus on its present state of development, the prospects for demonstration of production readiness, and a discussion of problem areas within this technology. The intent is to inform the user/designer of the options available for interfacing photonics (optics) to hydraulic power control actuators used in aerospace applications. Specifically, power and signal interfaces such as control, status and BIT (built in test) are considered. Mechanical interfaces such as optical connectors and fibers are also discussed. Other issues covered include the benefits of optics, reliability of components, and system architectures. The document draws on the expertise of numerous investigators who develop demonstration hardware, are familiar with photonics and specialize in hydraulic actuation, or are cognizant of aerospace fluid control systems. Contributions and suggestions have been supplied by members and attendees of the A-6D Committee.
A-6A3 Flight Control and Vehicle Management Systems Cmt
A new electrohydraulic steering technology offers energy efficiency improvements, increased productivity, enhanced safety, and adaptability to operating conditions, while also providing the capacity to support remote operation of a compact wheel loader. Remotely operated machines have been researched and developed in various industry sectors including military, automotive, agriculture, aerospace, and construction, to name a few. Remote operation is desired where conditions are deemed too hazardous for human operators to perform, as is the case with explosive mines, radioactive sites, outer space missions, and oil drilling structures. On the other hand, when the nature of the work performed is repetitive and requires less complex decision-making and problem-solving skills, autonomous operation can provide a viable alternative. Multiple researchers, in both academia and industry, have probed remote and autonomous operation of machines over the past few decades. A tele-operated skid steer loader was developed with two operator-machine interfaces and compared against a manually operated machine. Testing results demonstrated acceptable performance of the first interface employing a laptop computer with a steering wheel. Testing also showed that the operator-machine interface choice was task dependent, and handheld-computer control yielded good results in specific cases only.
Programs are helping hydraulic systems do more while reducing operator workloads. Digital controls continue to expand their reach, impacting everything from the intricacies of engine operations to the interactions between operator and machine. This takeover has driven an explosion in the amount of software running on all types of electronic control units (ECUs). Electrohydraulic systems have seen significant growth as most vehicles' overall volume of software soared. Programs control valves and other equipment, interact with operators, and ensure that safety regulations are met.
Costlow, Terry
Closer links between powertrains and hydraulic systems cut fuel usage and emissions while improving efficiency. As regulations including Tier 4 further restrict fuel consumption requirements, design teams are tightening the links between powertrains and hydraulic systems. Improving communications between the two can bring significant savings while also reducing size and weight. Advanced electronics permit matching the hydraulics demand and the engine load, which cuts fuel usage while improving hydraulic performance. Engines can run in their sweet spots longer and hydraulic systems can deliver power more quickly when they don't have to wait for engines to rev up. These revisions also help trim emissions.
Costlow, Terry
This SAE Aerospace Recommended Practice (ARP) provides guidance for the design and installation of a commercial aircraft hydraulic system to meet the applicable requirements, including the applicable airworthiness regulations that affect the hydraulic system design. This ARP also provides information and guidelines on the many factors that arise in the design process to provide cost effectiveness, reliability, maintainability and accepted design and installation practices.
A-6A1 Commercial Aircraft Committee
Modern on-road vehicles have been making steady strides when it comes to employing technological advances featuring active safety systems. However, off-highway machines are lagging in this area and are in dire need for modernization. One chassis system that has been receiving much attention in the automotive field is the steering system, where several electric and electrohydraulic steering architectures have been implemented and steer-by-wire technologies are under current research and development activities. On the other hand, off-highway articulated steering vehicles have not adequately evolved to meet the needs of Original Equipment Manufacturers (OEM) as well as their end customers. Present-day hydrostatic steering systems are plagued with poor energy efficiency due to valve throttling losses and are considered passive systems relative to safety, adjustability, and comfort. This paper introduces a novel scheme of an electro-hydraulic power steering system that utilizes a proven energy-saving technology, pump displacement control, which eliminates throttling losses associated with hydraulic control valves by controlling the displacement of a variable displacement pump. This new architecture lends itself to high energy efficiency resulting in lower fuel consumption and reduced emissions, higher machine productivity and reduced operator fatigue, and active safety functions that counteract instabilities and reject disturbances.
Daher, Naseem A.Ivantysynova, Monika
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