Industry Panel Session 2
October 14, 2022
Panel 2 – Applied Innovations
Moderator: Prof. Emma Frosina
The Future of Electronified Hydraulics
Bosch-Rexroth’s strategy of electronified hydraulics in the field of mobile hydraulics has advanced hydraulics and extended the possibilities for higher performance, productivity, efficiency and controllability. In order to exploit the capabilities of these new components and systems, advanced electronic controls have been developed and commercialized. An illustrative example is the high efficiency suite (HES) recently developed for loader type equipment. This suite comprises 1) a high-efficiency active ride control, and 2) an ECO+ mode that enables full regeneration for single and multiple actuators, a pump controlled operation principle for single and multiple actuator control that minimizes the implement pump stand-by pressure as well as valve metering losses.
Off-road electrified vehicle and hydraulics evolution
Electrification technologies in Agriculture and Construction machinery are becoming more and more important to provide an answer to those macrotrends like population growth, urbanization, connected devices and last but not least important the climate change. Example of electrification already in production are in place for Construction equipment while in Agriculture the introduction is behind but in progress through many prototypes.
Electrification is a newer trend that brings challenges like high cost of components and an evolution of the current vehicle functionalities like hydraulics, that will not disappear immediately. For this reason, efficient hydraulics, from single component to full system, will be key to battery powered machines and in general to minimize fuel consumption and reduce emissions for those vehicles that will remain in an “hybrid-electric” configuration because of the high power demand mission not favourable to be served by full electric architecture. It will be important to balance performances, cost and efficiency.
Another important aspect is related to the talent shift from mechanical supported by electronics to electronics supported by mechanical. Strategic core skills need to evolve with electronics, controls and software becoming a core element of every system present in the vehicle.
A new paradigm for improving energy-efficiency through Synchronous Reluctance Motor Technology
Electrification and Energy Efficiency represent two main drivers in motion technology developments. Among the many domains where energy saving can be sought, the efficiency of the primary power source is the most effective for achieving the efficiency objective at system level, both in industrial and mobile applications. In hydraulics systems for instance, fluid power is provided by a pump driven typically by an electric motor, similarly in electromechanical applications where the primary source of power is electric.
Advances in the Synchronous Reluctance Motor (SRM) Technology in connection with the development of cost-effective high-performance electronic drives open new perspectives for the realization of intrinsic efficient energy supply systems that can be used for motion. Duplomatic Motion Solution has been investing in this technology since a couple of years and will provide insight into the benefits of SRM the technology, comparing its characteristics and performance results with more traditional approaches.
Fluid-o-Tech: Smart Fluidics and Digitalization
Fluid-o-Tech has 70-year experience in moving, dosing and controlling fluids with high accuracy and precision by designing and producing volumetric pumps, valves and sensors for automotive, foodservice, industrial and healthcare industries. Driven by innovation, empowering new technologies and solutions for controlling fluids, Fluid-o-Tech anticipates customer needs, always staying ahead, leveraging on its multidisciplinary core.
The presentation from Fluid-o-Tech will provide a brief overview of how digitalization combined with high precision mechanics and fluid dynamics, is smartly embracing new challenges in different fields Finally, different strategies will be passed to share our vision, from the use of virtual simulation to the potential use of machine learning and implementation of digital-twin of our products.
Silent Modular Pumps Development
Marzocchi ELIKA pumps are also available in multiple versions for all groups 2, 3 and 4. Due to the stresses induced by the helical rotors, a special hydraulic compensator had to be developed and tested in order to connect the stages of the modular pumps and simultaneously axially compensate the pumps. The compensator between the stages not only transmits the torque to the rear stages, but also ensures the correct and continuous axial balancing of the helical gears as the operating pressure changes. The robust and compact patented stage connection system also makes it possible to have pumps with “mixed” configurations between the groups (e.g. 4+3). Multiple ELIKA pumps, despite the presence of the compensator, have reduced axial dimensions, slightly larger than those of a single-stage pump. The mechanical connections between the stages are obtained by means of splined connections in order to guarantee a high transmission torque between the stages. Multiple pump configurations with separate suction are also available, where the stages can work with different oils or on circuits with separate tanks. The heart of the product remains the special profile design, which eliminates the encapsulation phenomenon typical of normal gear pumps, removing the main cause of noise and vibration. The elimination of the encapsulated volume produces a drastic reduction in pressure fluctuations and vibrations that are usually transmitted to the other components connected to the pump. The study of the particular tooth profile was conducted in collaboration with the Faculty of Engineering of the University of Bologna, through the creation of dedicated design software. ELIKA reduces noise emission by an average of 15 dBA compared to a conventional external gear pump, with surprising results on larger displacements.
From Component to System: a change of approach for an efficient hydraulics
In order to achieve an efficient hydraulic system, that complies with the strict environmental regulations, it is essential to have high-performance components designed for minimum energy consumption. However, this is not enough, for an optimal energy balance it is essential to optimise the interaction of the components themselves, creating a system logic capable of maximising the efficiency.
A real change of paradigm for many manufacturers who, from a strong specialization on single components, broaden their research by integrating a holistic vision. Software and mechatronics, understood as the electrification of the components themselves, are the basis of this overall approach, as well as a deep knowledge of the machines and their modes of operation.
Here are some practical examples of the system approach: first of all the management of the interaction between pump and directional control valve, towards logics that go beyond the traditional load sensing systems, in order to contain the typical causes of dissipation; secondly, the interaction of hydraulic components with electric machines to generate energy recovery opportunities, still little exploited in the mobile machinery market.