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In the world of simulation software, many different approaches are used to obtain accurate hydraulic circuit simulation. Most of these tools model components as a set of mathematical equations parameterized with mechanical and geometric data for each component. They are able to simulate in depth specific functions of a circuit, however it becomes progressively a more demanding task to simulate more complex and complete systems. One of the key elements of simulation software is its ability to model valve performance in terms of flow characteristics, pressure drop and flow force. This also holds true for pumps and motors where the knowledge of efficiencies is required to achieve realistic duty cycle behavior. In this paper, the chosen approach is to demonstrate the efficiency of modeling components using a software downstream design methodology by implementing readily available performance curves and other characteristics of hydraulic components and functions. This downstream method of modeling components ensures the reliability and accuracy of systems behavior based on manufacturer specific data and allows for fast simulation of complete virtual machines which is impractical to achieve by traditional upstream programming. The simulation of a complete hydraulic system delivers global validation and analysis capabilities that can also be exploited beyond the engineering design scope including maintenance diagnostics and training activities. This paper will demonstrate that using Automation Studio™ ?a commercially available off-the-shelf drawing and simulation software tool that uses mainly downstream design? simulation data and OEM product information can be easily entered from a readily available hydraulic component vendor in order to create valves, pumps and motors for fast and accurate sizing and system simulation of a virtual machine. The ability to realistically simulate entire machines offers a unique capability to monitor, and study specific performance criteria such as: hysteresis, pressure drop, leakage, flow force, and other flow/pressure characteristics, power generation and transmission up to the full energy consumption at various operating conditions.
The necessity for greener and more efficient equipment has led OEMs and manufacturers to bring intelligence into fluid power systems. The integration of electronic controls in key components allow for better power management and safer work environment, which are two major concerns in the fluid power industry. One of the challenges of these new integrated solutions resides in the complexity of the design which involves many different expertise. Fluid Power, Electrical and Control Specialists need a communication platform to develop more efficient systems combining all technologies. Traditional control modeling methods are used to develop performant controllers with the help of equation-based or model-based software. However, more hybrid modeling methods – such as Machine Knowledge Management – are favored to design fluid power systems using integrated mechatronics software. By combining both methods to allow integration or co-simulation, control specialists will be properly integrated in the design and analysis process to build more intelligent machines.
A new generation of hydraulic components with their integrated control capability, provides more precision and flexibility, but brings implementation challenges. To cope with this changing reality, the fluid power industry needs to redefine work processes surrounding mechatronic machine development, including the creation of training programs. Although a new generation of students accustomed with numerical simulation technologies is starting to emerge, their applied knowledge is often very limited. In addition, experienced specialists who possess this expertise are also getting scarce and harder to replace. To facilitate this technological transition, simulation and numerical analysis tools seem promising. However, to truly be effective, these tools must enable a collaborative work environment that will leverage the machine knowledge of everyone involved in the development process. The goal of this paper is to provide hydraulic engineers with an optimized and integrated approach, in-line with the working process evolution. This approach is demonstrated by two case studies of electrohydraulic independent-metering valves systems. The first one is the development of a hydraulic and control simulation environment of a CMA Eaton valve. The second one studies the interactions of a virtual Sun Hydraulic valve system that regulates the actuator movement under different loads, co-simulated with a PLC.
The fluid power industry has seen significant changes in the last decade, following the electrification of hydraulic technologies. By adding intelligence to hydraulic and pneumatic manufacturers’ components, designing and testing new fluid power applications require the additional expertise of control specialists. Since fluid power and control specialists use different CAE tools to create and virtually test their respective design, there is a need to create an integrated test environment to better communicate, understand and specify requirements of electro-hydraulic systems. In this paper, we will demonstrate how virtual components up to a complete machine developed on simulation software can be controlled by physical control devices (joystick, controllers…) using CAN bus communication. Examples of this will be illustrated for virtual systems built according to manufacturers’ specifications in Automation Studio™ and communicating with the physical controllers: a hydraulic simulation model (ex.: Eaton CMA valves) communicating with a programmable controller and multiple devices as well as Eaton HFX Controller, Danfoss PLUS+1<SUP>®</SUP> microcontroller or HydraForce CoreTek controller.
How to take advantage of a Machine Knowledge Management Software to enlarge the simulation tool spectrum from the dynamics performances of individual components up to a complete mechatronic systems analysis & monitoring
It is well known that the current economic and market trends are pushing Original Equipment Manufacturers (OEMs) and system integrators to design high-performance systems with tighter development time requirements. Naturally these developers are resorting to simulations to avoid the time and cost of early prototyping. Without losing security and environmental sights, they also wish to reuse their simulation models for different needs and purposes. Automation Studio™ software establishes a new “language” of virtual machines and components that manufacturers of hydraulic, electrohydraulic and control component need to market and promote their products. This paper presents and innovative approach to aid design and analysis from simulation of dynamic component behaviours to complete mechatronic systems and machines. The proposed methodology allows the decision maker to select the appropriate simulation setting in order to meet the needs of multiple simulation scopes for every step in the project’s lifecycle. This approach used to be called Machine Knowledge Management Software.