Fluid and Mechatronic Systems at Linköping University Petter Krus

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1 Fluid and Mechatronic Systems at Linköping University Petter Krus

2 Motivation In Sweden Fluid power and heavy vehicles is an important industry. Sweden has twice as much fluid power per capita as Germany (and only second to Finland in that respect) Sweden has historically been dependent on Forestry and mining which has lead to strong development of heavy machinery with hydraulics. Also Aeronautics industry has been important (pumps) 3

3 LiU Partner Companies with Ongoing Projects Atlas Copco (Mining equipment, rock drills) National Instruments (Measurement and control) Parker (Fluid power components) Prevas (Testing systems) Saab AB (Aircraft) Scania AB (Trucks) Volvo CE (Construction Machinery) 4 48th AIAA Aerospace Sciences Meeting

4 Motivation Fluid power is an area which excels in the interaction between industry and university, and an example of a working innovation system. Collabprative research in component design Collbaorative research in system design for heavy vehicles Collaboration on system design for industrial automation Fluid power is underrepresented academically, but interdisciplinary and well connected to other disciplines. Only one laboratory in Sweden and one laboratory in Brazil Swedish companies has a strong presence in Brazil Can we create a Brazilian-Swedish network of fluid power? 5

5 Sid 6 Linköpings universitet

6 Increased Intelligence in Products New products tend to have more intelligence than before. This apply to a wide range of products. This is particularly true for: Cars Aircraft Construction Machinery This is in response to increased requirements for efficiency, driven by economics, safety, and environment. 7

7 Technologies Systems that are characterized by a close coupling between: Mechanical system Power transmission/actuation system Sensors Control System This requires, Multidisciplinary co-design, i.e. Mechanical design and control system co-design where modelling and simulation are central 8

8 Energy Efficient Mobile Hydraulic Actuation Systems Björn Eriksson Mikael Axin Original Load Sensing system (LS) with closed loop controlled pump Flow sharing system with open loop controlled pump 10

9 Karl Pettersson Energy Efficient Transmissions for Construction Machinery Hydromechanical transmission Hardware-in-the-Loop testbench 11

10 Transformer Based Energy Recuperation System Hydraulically connected energy storage system Kim Heybrok Karl Pettersson Hardware test bed Sid Linköpings universitet

11 Liselott Ericson Modelling of Fluid Power Machines Flow [l/min] Simulations can be in different shapes and comprehensive level with there own pros and cones. Pressure [Pa] 2.01e e7 With the knowledge from the CFD simulations and measurements, the accuracy of the fast 1D model can be increased. Time [ms] 13

12 Autonom Styrning av Tunga Fordon Lars Andersson Peter Nordin Aktiv styrning Genering av nytt koncept för servostyrning Minskad bränsleförbrukning HWIL Validera i rigg och lastbil Sid Linköpings universitet

13 Industrial Partners and Applications Helicopters Cybaero AB Construction Machines Volvo CE Hardware in the loop systems Rock drills Atlas Copco Prevas, National Instrument Sid Linköpings universitet

14 The HOPSAN Development Co-Simulation Graphical Model Generator Component Model Generator Optimisation Parallel Execution Model Gen. 1 Model Gen. 2 HWIL HIL Stiff DE Solver TLM Sub-data files and node system FFT and frequency domain analysis HOPSAN HOPSAN II Mainframe Computers Macintosh Workstations PC Computers 17 17

15 HOPSAN-NG (Next Generation) Bidirectional delay-lines Modelica support is under development Genuine team work Freeware that can be downloaded from Friday afternoon workshop= happy hour 18

16 Example: Aircraft System The aircraft attitudes during an S-maneuver. Angular position and reference position of the rudder actuator 19 48th AIAA Aerospace Sciences Meeting

17 Conceptual Aircraft Design (Saab) SIZING AND AERODYNAMICS Matlab Tango - Aircraft sizing Tornado- Aerodynamics Patrick Berry Kristian Amadori Christopher Jouannet Raghu Chaitanya Manjula Ingo Staack Modelica (Dymola) CATIA RAPID CPACS Hopsan 21

18 Ingo Staak FLUD/Vinnova, Saab AB Aircraft Environmental Control System: Conceptual system layouts of aircraft environmental control systems: Cabin Segment Bleed-less, based on electric compressors Integrated vapor cycle Thermal Management Faster than real time simulation in Dymola (factor ~300) Fusel age Total ECS system model Compressor Unit ECS Pack 22

19 Model Based Design Analysis and Optimisation Integration of different models such as system simulation models, aerodynamics and structural models. This allows for studying the effects of parameter changes on functional characteristics across the models Integrated models can be used for: Design sensitivity analysis. Study influence of uncertainty. System optimisation Simulation model Integrated system model Other analysis model Academic Forum May 23,

20 UAV Weight B Cr Ct tc lambda Range Liftoff distance Wing Wing Wing Wing Wing Wing Landing distance Takeoff weight Required weight quotient Optimal cruise speed Landing speed Liftoff speed Stall speed Emissions MTBF Cost Structure Structure Structure Structure Structure Structure Structure Airframe Propulsion system Systems Aircraft Aircraft Aircraft Aircraft Aircraft Aircraft Aircraft Aircraft Aircraft Aircraft Aircraft Mission Student Projects: From sketch to physical prototype in 5 months System Characteristics 5948,77 437,66 120, ,66 0,99 147,43 26,48 31,52 52, , , ,11 Range 5948,77 1,00-0,23-0,27-0,02-0,12 0,05-0,09-0,09-0,09-0,41-0,53 0,11 Actual Liftoff distance 437,66-0,10 1,00 0,32 0,11-0,13-0,24 0,22 0,22 0,22 0, ,97 0,13 System characteristics Unit Target value value 20,00 6,89 2,07 0,02 Landing distance 0,00 120,30-0,30 0,79 1,00 0,15-0,08-0,27 0,40 0,40 0,40 0,10-0,97 0, Range km 5000, ,87-0,09-0,45-0,10-0,02 Takeoff weight 0,00 0, ,66 0,66-0,19 0,301,81 1,10 1,00 0,00 1,00-0,51 2,05-0,50 1,08 0,50 0,50 0,50 0,70-6,51 1,31 Required weight quotient 0,99-1,24-2,92-0,70-0,69 1,00 0,60-0,50-0,50-0,50 0, ,71-1,32 Liftoff distance m 500,00 393,93-1,46-0,37-0,17 0,00 Optimal cruise 0,00 speed 2,01 147,432,01 0,22 1,26-2,38 1,69-1,06 0,00-0,29 0,26 4,96 1,00 0,00-0,84-0,84-0,84-0,21 1,90-0,38 Landing distance m 500,00 104,18-0,37-1,32-0,32 0,00 Landing speed 0,00 2,01 26,482,01-0,47 0,502,43 0,37 1,79 0,00 0,33-0,24 2,88-0,96 0,00 1,00 1,00 1,00 0, ,17 0,43 Liftoff speed 31,52-0,47 2,43 1,79 0,33-0,24-0,96 1,00 1,00 1,00 0,23-2,17 0,43 Takeoff weight N 60000, ,23 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,50 0,37 0,00 0,87 0, Stall speed 52,54-0,47 2,43 1,79 0,33-0,24-0,96 1,00 1,00 1,00 0,23-2,17 0,43 Required weight quotient 1,00 0,98 0,08-0,03-0,01-0,04 Emissions 0,00 0, ,86 0,16-1,00 0,430,56 0,27 0,23 0,00 0,23 0,16 0,86-0,11 0,00 0,11 0,11 0,11 1, ,00 0,00 MTBF 6769,23-0,07-0,28-0,11-0,11 0,10 0,06-0,06-0,06-0,06 0,00 1,00-0,17 Optimal cruise speed m/s 100,00 146,68-0,68-0,11-0,07-0,01 0,00 0,86 0,86 0,25 0,19 0,00 1,30 0, Cost 55384,11 0,40 1,08 0,64 0,64-0,48-0,32 0,32 0,32 0,32 0,00-4,96 1,00 Landing speed m/s 70,00 25,48-0,50-0,38-0,12 0,00 0,00 1,00 1,00 0,25 0,19 0,00 1,43 0, Liftoff speed m/s 70,00 30,33-0,50-0,38-0,12 0,00 0,00 1,00 1,00 0,25 0,19 0,00 1,43 0, Stall speed m/s 80,00 50,55-0,50-0,38-0,12 0,00 0,00 1,00 1,00 0,25 0,19 0,00 1,43 0,00 Number of simulations Emissions 10000,00 Sid 18869,74 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 1,00 0,00 1,00 0,00 MTBF hour 1000, ,98 0,00 0,00 0,00 0,00 0,00 0,00 0,00 4,27 0,00 1,00 5,27 0,00 Linköpings universitet Cost keur 40000, ,64 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,77 0,24 0,02 1,02 0,

21 The Electric and Hydraulic Propulsion Systems 36 cm 3 /rev Gerotor Accumulators 2.5 litres gas bladder accumulator Motor/pump Valve Motor/pump 25

22 Generic Future Fighter (GFF) Subscale Demonstrator Concept developed by Saab Subscale demonstrator build on request from FMV and Saab at Linköping University Project Goals Show a cost effective way, with short lead time, to design and manufacture a flying demonstrator of a concept, that can be used already in preliminary design, for project risk mitigation. Evaluate the usage of scaled demonstrators as a tool for aircraft development, e.g. as "flying wind tunnel". Sid Linköpings universitet Real Jet Engine with 170 N thrust a Length 2.4 m Span 1.5 m Weight 15 kg 13% scale

23 Subscale Flight Testing David Lundström Ingo Staack Methodology and instrumentation is developed on jet powered Rafael model. Subscale flight testing as flying wind tunnel Tufting for flow visualisation in flight In flight step response: Rudder deflection Page 27th Congress of the International Council 22/9/

24 Fluid and Mechatronic Systems Maintain and develop laboratory resources Modelling and simulation technologies Design analysis and system optimisation Applications: Mechatronics, hydraulics, construction machines, road vehicles, and aircraft. Keywords: System dynamics, and system efficiency Design model simulate analyse prototyping model validation evaluation and testing 28

25 Applied Research Eco System Research Researchers Research results/ Knowledge and experience PhD-program PhD-students PhD:s Industry Education Students Engineers 29 48th AIAA Aerospace Sciences Meeting