Similar articles

Abstract: The integrated valve-controlled cylinder combines various control and execution components in hydraulic transmission systems. Its precise control and rapid response characteristics make it widely used in mobile equipment for aerospace, robotics, and other engineering applications. additive manufacturing provides high design freedom which can further enhance the power density of integrated valve-controlled cylinders. However, there is a lack of effective design methods to guide the additive manufacturing of valve-controlled cylinders for more efficient hydraulic energy transmission. This study accordingly introduces an energy-saving design method based on additive manufacturing for integrated valve-controlled cylinders. The method consists of two main parts: (1) redesigning the manifold block to eliminate leakage points and reduce energy losses through integrated design of the valve, cylinder, and piping; (2) establishing a pressure loss model to achieve energy savings through optimized flow channel design for bends with different parameters. Compared to traditional valve-controlled cylinders, the integrated valve-controlled cylinder developed from our method reduces the weight by 31%, volume by 55%, and pressure loss in the main flow channel by over 30%. This indicates that the design achieves both lightweight construction and improved hydraulic transmission efficiency. This study provides theoretical guidance for the design of lightweight and energy-efficient valve-controlled cylinders, and may aid the design of similar hydraulic machinery.

一体化阀控缸节能设计与增材制造

[1]BarasuolV, Villarreal-MagañaOA, SangiahD, et al., 2018. Highly-integrated hydraulic smart actuators and smart manifolds for high-bandwidth force control. Frontiers in Robotics and AI, 5:51.

[2]BhattiJ, PlummerAR, IravaniP, et al., 2015. A survey of dynamic robot legged locomotion. International Conference on Fluid Power and Mechatronics, p.770-775.

[3]ColettiF, VerstraeteT, BulleJ, et al., 2013. Optimization of a U-bend for minimal pressure loss in internal cooling channels—part II: experimental validation. Journal of Turbomachinery, 135(3):051016.

[4]CrawfordNM, CunninghamG, SpenceSWT, 2007. An experimental investigation into the pressure drop for turbulent flow in 90° elbow bends. Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, 221(2):77-88.

[5]HagenD, PadovaniD, ChouxM, 2019. A comparison study of a novel self-contained electro-hydraulic cylinder versus a conventional valve-controlled actuator—part 1: motion control. Actuators, 8(4):79.

[6]Hashan PeirisLD, PlummerA, RoesnerJ, et al., 2021. Prediction of flow path pressure drops in curved galleries for additively manufactured hydraulic manifolds. Symposium on Fluid Power and Motion Control, No. V001T01A021.

[7]HeW, DengQH, YangGY, et al., 2021. Effects of turning angle and turning internal radius on channel impingement cooling for a novel internal cooling structure. Journal of Turbomachinery, 143(9):091005.

[8]HuangH, ZhangJH, XuB, et al., 2021. Topology optimization design of a lightweight integrated manifold with low pressure loss in a hydraulic quadruped robot actuator. Mechanical Sciences, 12(1):249-257.

[9]HuangY, LeuMC, MazumderJ, et al., 2015. Additive manufacturing: current state, future potential, gaps and needs, and recommendations. Journal of Manufacturing Science and Engineering, 137(1):014001.

[10]LangelaarM, 2018. Combined optimization of part topology, support structure layout and build orientation for additive manufacturing. Structural and Multidisciplinary Optimization, 57(5):1985-2004.

[11]McClainST, HansonDR, CinnamonE, et al., 2021. Flow in a simulated turbine blade cooling channel with spatially varying roughness caused by additive manufacturing orientation. Journal of Turbomachinery, 143(7):071013.

[12]NiraulaA, ZhangSZ, MinavT, et al., 2018. Effect of zonal hydraulics on energy consumption and boom structure of a micro-excavator. Energies, 11(8):2088.

[13]PadovaniD, RundoM, AltareG, 2020. The working hydraulics of valve-controlled mobile machines: classification and review. Journal of Dynamic Systems, Measurement, and Control, 142(7):070801.

[14]PietropaoliM, AhlfeldR, MontomoliF, et al., 2017. Design for additive manufacturing: internal channel optimization. Journal of Engineering for Gas Turbines and Power, 139(10):102101.

[15]Pratheesh KumarS, ElangovanS, MohanrajR, et al., 2021. Review on the evolution and technology of state-of-the-art metal additive manufacturing processes. Materials Today: Proceedings, 46:7907-7920.

[16]QuanZY, QuanL, ZhangJM, 2014. Review of energy efficient direct pump controlled cylinder electro-hydraulic technology. Renewable and Sustainable Energy Reviews, 35:336-346.

[17]RezazadehS, AbateA, HattonRL, et al., 2018. Robot leg design: a constructive framework. IEEE Access, 6:‍54369-54387.

[18]Satish PrakashK, NancharaihT, Subba RaoVV, 2018. Additive manufacturing techniques in manufacturing–an overview. Materials Today: Proceedings, 5(2):3873-3882.

[19]SchmidtM, MerkleinM, BourellD, et al., 2017. Laser based additive manufacturing in industry and academia. CIRP Annals, 66(2):561-583.

[20]ShangYX, LiuXC, JiaoZX, et al., 2018. An integrated load sensing valve-controlled actuator based on power-by-wire for aircraft structural test. Aerospace Science and Technology, 77:117-128.

[21]WangWJ, TangF, ZhengC, et al., 2022. Prototyping a novel compact 3-DOF hydraulic robotic actuator via metallic additive manufacturing. Virtual and Physical Prototyping, 17(3):617-630.

[22]WeaverJS, HeigelJC, LaneBM, 2022. Laser spot size and scaling laws for laser beam additive manufacturing. Journal of Manufacturing Processes, 73:26-39.

[23]WuGH, YangJH, ShangJZ, et al., 2020. A rotary fluid power converter for improving energy efficiency of hydraulic system with variable load. Energy, 195:116957.

[24]WuXD, BaiWB, XieYE, et al., 2018. A hybrid algorithm of particle swarm optimization, metropolis criterion and RTS smoother for path planning of UAVs. Applied Soft Computing, 73:735-747.

[25]XieGL, DongYJ, ZhouJ, et al., 2020. Topology optimization design of hydraulic valve blocks for additive manufacturing. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 234(10):1899-1912.

[26]XuZQ, LiWL, LiuXY, et al., 2019. Dynamic characteristics of coupling model of valve-controlled cylinder parallel accumulator. Mechanics & Industry, 20(3):306.

[27]ZhangC, WangS, LiJ, et al., 2020. Additive manufacturing of products with functional fluid channels: a review. Additive Manufacturing, 36:101490.

[28]ZhangH, WangCY, LiCC, 2019. Optimization of flow channel in 3D printing hydraulic manifold block based on response surface method. The 8th IEEE International Conference on Fluid Power and Mechatronics, p.217-223.

[29]ZhangJH, ChaoQ, XuB, 2018. Analysis of the cylinder block tilting inertia moment and its effect on the performance of high-speed electro-hydrostatic actuator pumps of aircraft. Chinese Journal of Aeronautics, 31(1):169-177.

[30]ZhouL, ZhuY, LiuHH, et al., 2021. A comprehensive model to predict friction factors of fluid channels fabricated using laser powder bed fusion additive manufacturing. Additive Manufacturing, 47:102212.