Name: a modeling and simulation method for preliminary design of an electro-variable displacement pump
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Description: Watch this Scientific Journal Video about A Modeling and Simulation Method for Preliminary Design of an Electro-Variable Displacement Pump at JoVE.com

The authors acknowledge the Beijing Institute of Precision Mechatronics and Controls for supporting this research.

NOTE: Matlab and Simcenter Amesim (referred to as system simulation platform hereafter) were used in this protocol and are listed in the Table of Materials. However, the proposed protocol is not limited to implementation in these two software applications.
1. Selecting and classifying the EVDP design parameters (Step 1 in Figure 2).
<ol>
	<li>Dismantle the architecture of the EVDP in Figure ...

<ol>
	<li>Ketelsen, S., Padovani, D., Andersen, T. O., Ebbesen, M. K., Schmidt, L. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Classification+and+review+of+pump-controlled+differential+cylinder+drives.">Classification and review of pump-controlled differential cylinder drives.</a> Energies. 12 (7), 1293 (2019).</li><li>Alle, N., Hiremath, S., Makaram, S., Subramaniam, K., Talukdar, A. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Review+on+electro+hydrostatic+actuator+for+flight+control.">Review on electro hydrostatic actuator for flight control.</a> International Journal of Fluid Power. 17 (2), 125-145 (2016).</li><li>Garrison, M., Steffan, S. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Two-fault+tolerant+electric+actuation+systems+for+space+applications.">Two-fault tolerant electric actuation systems for space applications.</a> 42nd AIAA/ASME/SAE/ASEE Joint Propulsion Conference &amp; Exhibit. , (2006).</li><li>Smith, S., Irving, J. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Electro+hydrostatic+actuators+for+control+of+undersea+vehicles.">Electro hydrostatic actuators for control of undersea vehicles.</a> Joint Undersea Warfare Technology Fall Conference. , (2006).</li><li>Gao, B., Fu, Y., Pei, Z., Ma, J. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Research+on+dual-variable+integrated+electro-hydrostatic+actuator.">Research on dual-variable integrated electro-hydrostatic actuator.</a> Chinese Journal of Aeronautics. 19 (1), 77-82 (2006).</li><li>Yan, X., Yu, L., Pan, J., Fu, J., Fu, Y. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Control+dynamic+performance+analysis+of+a+novel+integrated+electro+mechanical+hydrostatic+actuator.">Control dynamic performance analysis of a novel integrated electro mechanical hydrostatic actuator.</a> The Proceedings of the 2018 Asia-Pacific International Symposium on Aerospace Technology (APISAT 2018). 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The concept and other technical components of the EVDP have been presented in previous publications6,31, demonstrating the applicability and advantages of the EVDP. Instead of studying the EVDP itself, this paper continued to study the design method in relation to future real application needs. A specific design method is necessary for this type of highly integrated and multidisciplinary coupling product, which calls for delicate performance trade-offs and optimi...

Electro-hydrostatic actuators (EHAs) are receiving increasing interest for applications such as industrial presses, large mobile machinery, crane manipulators, and primary aircraft control due to their combination of the advantages of both electric actuators and hydraulic actuators1. Two basic types of EHAs can be identified: variable-speed EHAs and variable-displacement EHAs2. Currently, the variable-speed EHA is more popular than the variable-displacement EHA due to its higher efficiency and simplicity. However, along with the higher power level of the EHA, which is needed in heavy vehicles, such as heavy launch vehicles3 and submarines4, the driving motor and associated electronics of the variable-speed EHA have issues related to low dynamics, high thermal dissipation, high price, etc. Therefore, the variable-displacement EHA is being reconsidered for these high-power applications (&#62;30 kW), as its control is realized via a low-power device that regulates the pump displacement.
One major concern that prevents variable-displacement EHA being taken as a priority is its cumbersome pump displacement control unit, which itself is a complete valve-controlled hydraulic system. The electro-variable displacement pump (EVDP) has been proposed to address this issue by using a compact electric displacement control unit. This design improves the compactness, efficiency, etc., of the variable-displacement EHA, which resolves the previous weakness to a certain degree. Therefore, the use of variable-displacement EHAs for high-power applications may be facilitated by using the newly proposed EVDP. However, the complexity of the EVDP is significantly greater compared to the conventional hydraulically controlled variable-displacement pump as it integrates components from several new disciplines. Consequently, specific EVDP-based research activities have emerged. Our research group started the EVDP research5 and has continued to develop it6. Liu developed the EVDP for EHA applications and performed experimental tests7. Some hydraulic companies also provide EVDP products. In addition to the research regarding the technical components of the EVDP, the design method for responding to real application requirements is also significant for enhancing the EVDP&#39;s competence by further reducing the cost of using EVDPs and exploring their performance potential. Hence, a specific EVDP preliminary design method is necessary for optimizing trade-offs in its system-level performance by analyzing its coupled disciplines. The simulation-based preliminary design is of interest for this type of multidisciplinary coupling of mechatronic products8.
Although no specific simulation models for EVDP preliminary design have been proposed due to it being a newly proposed concept, much research has been invested in related mechatronic products. A dynamic EHA model has been built to optimize the weight, efficiency, and control performance in preliminary design9, but the lifetime, reliability, thermal characteristics, etc., were not involved, which are essential performance indexes that should be considered in preliminary design. Another dynamic EHA model has also been used to optimize cost, efficiency, and control performance10, and a thermal model was subsequently developed to evaluate the thermal characteristics of the optimized EHA11, but the reliability and lifetime were not considered. A comprehensive electro-mechanical actuator (EMA) preliminary design method has been presented12. Specific models with different functions capable of analyzing different characteristics have been proposed for this method, and reliability and lifetime models have also been developed13. The mechanical strength, power capability, thermal performance, etc., could hereby be evaluated, but the control performance was not involved. Another EMA preliminary design method utilized a dynamic EMA model and associated component sizing models14. The cost, weight, fatigue life, power capacity, physical constraints, etc., were involved in the simulation analysis, but reliability and control performance were not included. A dynamic model was proposed for the optimization design of a hydraulic hybrid drive train15. The power capacity, efficiency, control, etc., could be simulated, but the reliability and life were not considered. Models for analyzing an EHA-based flight control actuation system have been proposed, within which simple power transmission equations and weight functions were used16. Considering that the models were used for vehicle-level and mission-level analyses, the limited attribute coverage of the models was appropriate. As a major component of the EHA, servo motors have attracted separate attention regarding modeling and design, and the results are also instructive for EHA model development. Thermal networks, weight models, etc., can also be considered for EHA modeling17,18,19. The reviewed literature indicates that, even considering the results from products related to the EVDP, the developed models do not analyze all the influential performance attributes of the products for the preliminary design. The control performance, thermal performance, reliability, and lifetime are the attributes that have been most neglected in construction of the models. Therefore, this paper proposes a model package capable of analyzing all the most influential performance attributes for the EVDP preliminary design. The simulation analysis is also presented to better illustrate the model functions. This paper is an extension of a previous publication20, as it improves the parameter generation, involves the lifetime model, reliability model, and control model, optimizes the calculation cost, validates the model, and conducts in-depth simulation analysis, etc.
The conventional hydraulic control unit of a variable-displacement piston pump is replaced with an electric actuator to improve the compactness and reduce heat dissipation, as shown in Figure 1. The electric actuator consists of a ball screw, a gearbox, and a permanent magnet synchronous motor (PMSM). The electric actuator connects the swashplate via a bar to regulate the pump displacement. When applied in EHAs, the EVDP swashplate rotational position is closed-loop controlled by modulating the PMSM. The electric actuator is integrated with the piston pump in a mutual case to form an integral component. This design submerges the electric actuator in the working fluid and hereby strengthens the multi-domain coupling effects.
As the EVDP is a typical multi-domain mechatronic product, its preliminary design plays an essential role in optimizing trade-offs in its system-level performance and outlining the component design requirements. The process is illustrated in Figure 2 based on the simulation-based design scheme10,12. Step 1 firstly analyzes the selected EVDP architecture, as in Figure 1, and concludes the design parameters based on the specified performance requirements. Then, the design task is usually transformed into an optimization problem to explore the performance optimization of the EVDP. This is carried out by converting the design parameters into optimization variables and converting the performance requirements into objectives and constraints. It is worth noting that the design parameters need to be classified into active, driven, and empirical categories. Only the active parameters are used as optimization variables due to their independence features. The other two categories are automatically generated by estimation from the active parameters. Therefore, Step 2 develops the estimation models of the driven and empirical parameters. These estimation tools are used in each iteration of the optimization, as well as in Step 5 for formulating all the required simulation parameters. Step 3 builds the calculation models for each optimization objective or constraint, which reflects the required performance. These models should be computationally efficient; otherwise, the optimization calculation cost would be unacceptable. Step 4 performs the optimization calculation, which is usually multi-objective and multidisciplinary. It also deals with the parameter uncertainties in the preliminary design phase. Step 5 constructs an overall model of the designed EVDP and uses it for validating the optimization results by simulating the EVDP under typical duty cycles. This model is the ultimate tool for evaluating the preliminary design results. Therefore, this model should have the highest fidelity and involve all the influential characteristics in a tight coupling style. Finally, the preliminary design performance results and the system-level dimensioning results are obtained.
This paper focuses on the system modeling and simulation method of the EVDP, which involves conducting the parameter analysis in Step 1 and completing Steps 2 and 5. Firstly, the design parameters are derived based on the EVDP architecture and the design requirements, and they are classified into three sub-categories. Secondly, the estimation models for the non-active parameters are developed based on scaling laws, component catalogs, empirical functions, etc. Thirdly, the overall model of the EVDP is constructed using multidisciplinary coupling equations and additional lifetime and reliability sub-models, and the model is partially verified by experiments. Lastly, the previous sizing results are imported into the constructed model to perform simulation analysis under typical duty cycles. The system-level performance is deduced based on the simulation results. The parameter sensitivity and the robustness of the design are also evaluated. As a result, this paper develops a specific modeling and simulation method for EVDP preliminary design. The EVDP&#39;s performance for application in the EHA is comprehensively predicted. The proposed method stands as a practical tool for developing EVDPs and variable-displacement EHAs for high-power applications. The method can also be referred to for developing simulation tools for other types of mechatronic products. The EVDP in this paper refers to the electro-mechanically controlled variable-displacement pump, but the electro-hydraulically controlled variable-displacement pump is out of the scope of this paper.

<table border="1" fo:keep-together.within-page="1" fo:keep-with-next.within-page="always">
	<tbody>
		<tr>
			<td>Ball screw</td>
			<td>NSK</td>
			<td>PSS</td>
			<td></td>
		</tr>
		<tr>
			<td>EVDP prototype</td>
			<td>Beijing Institute of Precision Mechatronics and Controls</td>
			<td>customized</td>
			<td>7.4 mL/rev, 7000 rpm, 21 Mpa</td>
		</tr>
		<tr>
			<td>EVDP testrig</td>
			<td>Beijing Institute of Precision Mechatronics and Controls</td>
			<td>customized</td>
			<td>Refer to Figure 7, can be adapted upon individual needs. Including Power PMAC controller, ELMO Whistle Driver, etc.</td>
		</tr>
		<tr>
			<td>Gearhead</td>
			<td>Maxon</td>
			<td>GP</td>
			<td></td>
		</tr>
		<tr>
			<td>Matlab</td>
			<td>Mathworks</td>
			<td>R2020a</td>
			<td></td>
		</tr>
		<tr>
			<td>Permannet magnet synchronous motor</td>
			<td>Maxon</td>
			<td>393023</td>
			<td></td>
		</tr>
		<tr>
			<td>Piston pump</td>
			<td>Bosch Rexroth</td>
			<td>A10VZO</td>
			<td></td>
		</tr>
		<tr>
			<td>Simcenter Amesim</td>
			<td>Siemens</td>
			<td>2021.1</td>
			<td>system simulation platform</td>
		</tr>
	</tbody>
</table>

a modeling and simulation method for preliminary design of an electro-variable displacement pump

Electro-hydrostatic actuators (EHAs) have been considerably researched in academia, and their applications in various industrial fields are expanding. The variable-speed EHA has now taken priority over the variable-displacement EHA, but its driving motor and associated electronics encounter issues when applied in high-power applications: low-dynamics, high thermal dissipation, high price, etc. Therefore, a variable-displacement EHA equipped with an electro-variable displacement pump (EVDP) has been considered. The EVDP itself is a mechatronic system that integrates a piston pump, a ball screw, a gearbox, and a permanent magnet synchronous motor (PMSM). Consequently, the EVDP needs to be investigated to ensure its system-level performance when applied in an EHA. In addition to the previous research on the technical parameters of the EVDP, a dedicated design method is necessary for further reducing the cost of using the EVDP and exploring its performance potential. Here, a simulation based EVDP preliminary design method is selected for designing a 37 kW EVDP. Firstly, a previously proposed multidisciplinary model of the EVDP is extended by improving the parameter generation, including the EVDP life, reliability, control models, etc. Secondly, the proposed model is partially verified using a downsized prototype. Thirdly, the EVDP is simulated at a system level, supported by the proposed model. The EVDP performance is evaluated according to the specified design requirements. The temperature, bandwidth and accuracy, reliability and lifetime, etc., are all predicted for the EVDP. The simulation results demonstrate the EVDP's applicability in variable-displacement EHA. The proposed modeling and simulation method can be used to evaluate diverse EVDP performance and respond to general design requirements. The method can also support the resolution of the preliminary design challenges in terms of limited information and robustness. Therefore, the proposed method is appropriate for the realization of the simulation-based EVDP preliminary design method.

This section presents the results obtained from performing all the protocol steps, which constitute part of Step 1, all of Step 2, and all of Step 5 of the EVDP preliminary design method in Figure 2. The input information in the protocol includes the EVDP schematics in Figure 1, the optimized active parameters (clarified in Step 5.1.1.) of the EVDP from Step 4 of Figure 2, and the EVDP performance simulation tasks, which relate to t...

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A Modeling and Simulation Method for Preliminary Design of an Electro-Variable Displacement Pump

A simulation model specifically supporting the preliminary design of an electro-variable displacement pump (EVDP) is developed and partially verified by experiments. The control performance, life, reliability, etc., can all be evaluated using the proposed model, which covers the main performance requirements under the EVDP preliminary design task.

Electro-hydrostatic actuators (EHAs) have been considerably researched in academia, and their applications in various industrial fields are expanding. The ...

Electro hydrostatic activators support for the electrification of heavy duty systems. To achieve less energy consumption, our method concentrates on optimization, electro variable displacement pump utilization of the systems. Our modeling, and the simulation method supports the preliminary design.Our electro variable displacement pump, which should choose complete performance prediction, automatic parameter generation, and design robustness. Begin by classifying the parameters to design the electro variable displacement pump or EVDP. Assign the independent parameters, representing each component to the active category, and the parameters derived from the active parameters to the driven category.Then designate the parameters calculated, using empirical functions to the empirical category. To develop the estimation models, estimate the pump and motor driven parameters from the active parameters, using the scaling laws. Use the component catalogs to estimate the driven parameters for the gearbox and the ball screw from the active parameters.Assess the pump, the gearbox, and the ball screw efficiencies by empirical functions, and estimate the thermal resistances for the thermal network model developed with the empirical functions from the thermodynamics theory. Build the weight model of the EVDP in MATLAB by adding up the weights of each component and then conducting the dynamic lumped parameter modeling of the EVDP in the system simulation platform. Next conduct thermal modeling of the EVDP in the system simulation platform by setting a thermal network for the EVDP.For lifetime and reliability modeling, use the fatigue life of the ball and the wear life of the piston pump unit as its lifetime. Model the ball screw and piston pump unit lifetime with the equations. Assume the reliability of the ball screw and the pump corresponding to its lifetime, is 0.90, and define the reliability as calculated at the 50, 000th working hour.Then model the ball screw and piston pump unit reliability with the equation. Proceed to assemble the model by placing all the equations of each node together to form the model block for each node. Then conclude the input and output variables of each node.Define the inputs and outputs of the overall EVDP model and perform the causality analysis of all the nodes. When necessary add additional nodes to ensure that all the nodes are causally linked. Then connect all the nodes to form the overall model of the EVDP.Once the EVDP model is formed, verify the modeling method using the EVDP prototype and test rig. To do so, install the EVDP on a test rig, consisting of a loading part and a control part. Then connect the three EVDP ports to the hydraulic circuit of the loading part, and the EVDP electric cables to the control part.Conduct the prototype testing by pushing the start button on the panel and starting the auxiliary hydraulic power. After deactivating the mode valve with the button on the panel, set the sweeping frequency displacement command to the EVDP in the text box of the user interface. Record the EVDP displacement response, and derive its magnitude and phase characteristics.To analyze the experimental results set the active parameters of the EVDP prototype to the model built earlier. The model will generate other required simulation parameters automatically. Set the environment temperature, and initial EVDP temperature at 40 degrees Celsius, and run the simulation model under the same conditions as the EVDP prototype test to record the simulation results.To check the model accuracy, plot the experimental and simulation results of each condition group in one figure. To perform the simulation analysis of the EVDP design, set the dynamic and thermal models by clicking on the parameter mode tab and selecting the TFFD31 option. Then go to the file name for simple fluid characteristic data tab to import the oil property file.Under the parameter mode use the THGCV01 or THGCV02 blocks. To set the environment temperature as described in the manuscript input the active parameters to the parameter estimation models. Then click on the run button under editor tab to run the script for generating all the simulation parameters.In MATLAB, use the run button under editor tab to run the script for calculating the weight and activating the dynamic and thermal models with the simulation parameters. The simulation results will be obtained by the script automatically. With the run button under editor tab, run the script for calculating the EVDP lifetime and reliability performance from the saved simulation results.Go to the simulation mode in the system simulation platform to check the results. Then derive other EVDP performance results from these time domain simulation results. To set the simulation parameters, check the parameter mode.Then use the run button under editor tab to run the script for activating the dynamic and thermal models. Later, press the simulation mode tab to check the sensitivity and uncertainty analyses. The temperature dynamics of different EDVP parts are shown here.The representative analysis illustrates the EVDP efficiency under a full duty cycle. Under the full load condition, the EVDP achieved a total efficiency of around 80%Later, the absolute losses of the EVDP dropped, along with the efficiency decrease. The sweeping frequency response examined the EVDP dynamic performance.In the projected performance of the EVDP, a good control accuracy with a 0.09 degree error was predicted, whereas pump lifetime and reliability was found to be the weakest. After building the proposed models, the complete preliminary design method can be developed. The method can enhance the applicability of the electro variable displacement pump, and the associated electro hydrostatic activators.This method resolved common challenges of design stage, such as parameters certainty, and multidisciplinary simulations. This leads to more reliable, preliminary design of the pump for electro hydrostatic activators.

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