Modelling, Testing and Analysis of a Regenerative Hydraulic Shock Absorber System
<p>Schematic view of the design concept for a regenerative shock absorber system.</p> "> Figure 2
<p>The schematic view of fluid flows in shock absorber body and hydraulic rectifier.</p> "> Figure 3
<p>Key components of regenerative shock absorber system.</p> "> Figure 4
<p>Known and uncertain parameters and variables in power regeneration unit and hydraulic system.</p> "> Figure 5
<p>(<b>a</b>) Online voltage constant coefficient vs internal resistance; (<b>b</b>) online fitted torque constant coefficient, <span class="html-italic">k</span><sub>T</sub>.</p> "> Figure 6
<p>Fitted viscous friction torque based on online pressure and speed measurements.</p> "> Figure 7
<p>View of experimental generator test set up.</p> "> Figure 8
<p>(<b>a</b>) Offline fitted voltage constant; (<b>b</b>) offline fitted torque constant.</p> "> Figure 9
<p>(<b>a</b>) Bulk modulus variation with motor pressure; (<b>b</b>) predicted motor pressures for different bulk modulus values.</p> "> Figure 10
<p>Determined parameters and variables in power regeneration unit and hydraulic system.</p> "> Figure 11
<p>Predicted and measured pressure at (<b>a</b>) 0.5 Hz frequency and 25 mm amplitude; and (<b>b</b>) 1.0 Hz frequency and 20 mm amplitude (<span class="html-italic">R</span> is equal to the external load <span class="html-italic">R</span><sub>L</sub> and <span class="html-italic">V</span> is the same as accumulator capacity <span class="html-italic">V</span><sub>c</sub>).</p> "> Figure 12
<p>Predicted and measured motor speed at (<b>a</b>) 0.5 Hz frequency and 25 mm amplitude; and (<b>b</b>) 1.0 Hz frequency and 20 mm amplitude.</p> "> Figure 13
<p>Predicted and measured voltage at (<b>a</b>) 20 Ω load resistance; and (<b>b</b>) 40 Ω load resistance.</p> "> Figure 14
<p>Predicted and measured power at (<b>a</b>) 20 Ω load resistance; (<b>b</b>) 40 Ω load resistance.</p> "> Figure 15
<p>(<b>a</b>) Measured displacement-force loops; (<b>b</b>) measured velocity-force loops, at 11 Ω, 20 Ω, 30 Ω and 40 Ω load resistances.</p> "> Figure 16
<p>(<b>a</b>) Predicted motor pressure; (<b>b</b>) predicted shaft speed; (<b>c</b>) predicted regenerative power; (<b>d</b>) predicted power regeneration efficiency, at 0.16 L, 0.32 L, 0.50 L and 0.75 L accumulator capacities.</p> "> Figure 17
<p>(<b>a</b>) Measured motor pressure; (<b>b</b>) measured shaft speed; (<b>c</b>) measured regenerative power; (<b>d</b>) measured power regeneration efficiency, at 0.16 L, 0.32 L, 0.50 L and 0.75 L accumulator capacity.</p> "> Figure 18
<p>The calculation process of the measured volumetric efficiency.</p> "> Figure 19
<p>Hydraulic motor volumetric efficiency between predictions and measurements at 0.16 L, 0.32 L, 0.50 L and 0.75 L accumulator capacities.</p> "> Figure 20
<p>(<b>a</b>) Measured displacement-force loops; (<b>b</b>) measured velocity-force loops, at 0.16 L, 0.32 L, 0.50 L and 0.75 L accumulator capacities.</p> ">
Abstract
:1. Introduction
2. System Schematic
3. System Modelling and Prototype Development
3.1. Hydraulic Flow
3.1.1. Vibration Excitation
3.1.2. Flow across Check Valves
3.1.3. Gas-Charged Accumulator Flow
- (1)
- The gas-charged accumulator is assumed to be adiabatic, ignoring the heat exchange that happens between the gas and oil under conditions of rapid-cycling.
- (2)
- There are no frictions or thermal losses occurring during the charge/discharge cycles in the accumulator model. When the accumulator is running under variable pressure, thermal losses caused by variation in the gas temperature will inevitably influence gas behaviour.
- (3)
- The pressures in the fluid chamber instead of those in the gas chamber are used for flow rate calculation, which is reasonable because of the transient pressure balance inside the accumulator.
3.1.4. Flow through the Hydraulic Motor
3.2. Rotational Motion
3.3. Electrical Power
3.4. Fabrication of the Prototype
3.5. Test System and Measurement
4. Parameter Studies
4.1. Power Regeneration System
4.2. Hydraulic System
- Firstly, the hydraulic cylinder was assumed to be frictionless and without leakage.
- Secondly, in Equation (20), the mean values of the time-varying pressure and speed of the motor were taken as the nominal pressure drop (for the calculation of the hydraulic motor leakage coefficient) and the nominal shaft speed, respectively.
- Thirdly, the values of kT and kV were used as determined in Section 4.1, meaning that there are no additional electrical losses in the generator model to be accounted for, hence it can be assumed that the hydraulic motor power output Pm is equal to the power captured in the generator Pcap.
5. Results and Discussion
5.1. Validation Using Excitations
5.2. Validation Using Different Load Resistances
5.3. The effect of Accumulator Capacity
6. Conclusions
Acknowledgments
Author Contributions
Conflicts of Interest
References
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Name | Specification | ||
---|---|---|---|
Cylinder | Middle point, S0 = 100 mm, Full stroke, 200 mm | Piston area, Dcap = 50 mm, Annulus area, Drod = 30 mm | Max. pressure, 200 bar |
Motor | Displacement, Dm = 8.2 cc (cm3/rev) | Max. speed, 245 rad/s | Max. power, <6000 W |
Generator | Internal inductance, Lin = 0.015 H | 2.33 Phase magnetic field, Built in rectifier, Max. speed, 215 rad/s | Max. current, 10 A, Max. power, <2450 W |
Accumulator | Diaphragm accumulator | Port diameter, Dacc = 12.7 mm | Pre-charge pressure, Ppc = 20 bar |
Check Valve | Diameter: 3/8′ (≈9.525 mm), BSPP | Max. pressure, 350 bar | Preload pressure, Pcv = 0.7 bar |
Four Post Simulator | Maximum velocity, 1.9 m/s | Static load, 550 kg | Preload, 60 kg |
Hose | Hose diameter, Dh = 3/8′ | Length, L = 1 m | Max. pressure, 800 bar |
Shock Absorber Oil | Density, ρ = 872 kg/m3 | Viscosity, σ = 22 cSt | - |
Name | Symbol | Value | Unit | Name | Symbol | Value | Unit |
---|---|---|---|---|---|---|---|
Accumulator inlet area | Aacc | 1.27 × 10−4 | m2 | Flow coefficient | Cq | 0.7 | - |
Full piston face area | Acap | 1.96 × 10−3 | m2 | Specific heat ratio | k | 1.4 | - |
Check valve area | Acv | 3.93 × 10−5 | m2 | Cylinder dead volume | Vcyd | 1 × 10−8 | m3 |
Pipe area | Ap | 7.85 × 10−5 | m2 | Accumulator dead volume * | Vagd | 1%∙Vc | m3 |
Annular area of piston | Arod | 1.26 × 10−3 | m2 | Initial volume of cap-end chamber | Vic | 3.93 × 10−4 | m3 |
Discharge coefficient | Cd | 0.7 | - | Initial volume of rod-end chamber | Vrc | 6.38 × 10−4 | m3 |
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Wang, R.; Gu, F.; Cattley, R.; Ball, A.D. Modelling, Testing and Analysis of a Regenerative Hydraulic Shock Absorber System. Energies 2016, 9, 386. https://doi.org/10.3390/en9050386
Wang R, Gu F, Cattley R, Ball AD. Modelling, Testing and Analysis of a Regenerative Hydraulic Shock Absorber System. Energies. 2016; 9(5):386. https://doi.org/10.3390/en9050386
Chicago/Turabian StyleWang, Ruichen, Fengshou Gu, Robert Cattley, and Andrew D. Ball. 2016. "Modelling, Testing and Analysis of a Regenerative Hydraulic Shock Absorber System" Energies 9, no. 5: 386. https://doi.org/10.3390/en9050386