ERC for Compact

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ERC for Compact Efficient Fluid Power

• ERC 2006 Annual Meeting
• 1 December 2006

Kim A. Stelson, Professor Center
Director Department of Mechanical
Engineering University of Minnesota Website
www.fperc.org
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What is fluid power?

• Advantages of fluid power
• Excellent power to weight/size ratio
• Capable of extremely large forces
• Flexible and relatively easy to control

• Current uses
• Heavy equipment
• Construction industry
• Off-road vehicles
• Manufacturing

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Fluid Power is Unique. It has unparalleled
torque, power and bandwidth for the same weight
or volume. Example Power/Weight (kW/kg)
Pneumatic Motor 0.3-0.4 Hydraulic
Motor 0.5-1.0 Electric Motor 0.03-0.1 Fluid
power weight advantage 101 Reference I. L.
Krivts and G. V. Krejnin, Pneumatic Actuating
Systems for Automatic Equipment, Taylor and
Francis, 2006.

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• Fluid Power is Pervasive
• Used in aerospace, agriculture, construction,
  manufacturing, medical, mining and
  transportation.
• Over half of all industrial products have fluid
  power critical components almost all
  manufacturing uses fluid power.
• 3. Component sales are 12 billion (USA) and 33
  billion (worldwide). Systems sales are one to two
  orders of magnitude higher.

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Fluid Power is Growing
Source US Census Bureau Industrial Report for
Fluid Power, based on an annual Survey of US
manufacturers. 2005 includes NFPA estimates for
Nov/Dec. Estimated Growth for 2006 is a composite
based on several independent forecasts.
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• But, Fluid Power has Challenges
• Efficiency improvements required
  Efficiency Thrust
• Further reductions in size and weight
  Compactness Thrust
• 3. Noisy, leaky, difficult to use
  Effectiveness Thrust

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Vision The vision of the Engineering Research
Center for Compact and Efficient Fluid Power
(CCEFP) is to transform fluid power so that it is
compact, efficient and effective. This will
benefit humanity by significantly reducing energy
consumption and spawning whole new industries. A
coordinated research and education program will
facilitate this transformation.
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Energy Importance

• Sector Energy cost/yr. Savings (10
  improve)
• Agriculture, Mining and Construction 28
  B 2.8 B
• Manufacturing (machine drives only) 42 B 4.2
  B
• Total 70 B 7.0 B
• Source U. S. Dept. of Energy, Annual Energy
  Review 2004, Report No. DOE/EIA 0384(2004)

Each 10 improvement in energy efficiency in
these sectors will result in a savings of 7
Billion/year.
Goal 1 Dramatic improvement in efficiency of
fluid power
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Quantification of energy savings

• Example 1 Excavator
• Assume typical load cycle in a load sensing
  system (Eggers, et. al, 2005)
• Loss due to throttling 18
• Pump loss 18
• Line loss 2
• Piston loss 2
• Useful work 60
• ERC research
• Eliminate throttling losses (1A,1E)
• Reduce pump loss by 30 (1B,1C)
• Reduce line loss by 30-40 (1D)
• Enable regeneration (1A, 1B, 1E)
• Efficient human interface (3A)
• 30 saving 1.15 billion/yr. for earthmoving
  equipment

100 units of energy
50-70 units of energy depending on whether load
cycle permits regeneration
Literature cited by SVT suggests that 30 of
actual work can be obtained from regeneration
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Quantification of energy savings

• Example 2 Injection Molding Machine
• 180 ton hydraulic machine
• Consumes 32.1kW power
• Heater 3.2kW
• Hydraulics 28.9kW
• (23.9kW is lost through throttling)
• ERC research
• Throttle-less control configurations (1A, 1E)
• Reduced leakage (3D)
• Projected power 8.2kW
• 74 savings

148 million/yr. for 20 market penetration
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Energy Savings Transportation
Sector Energy cost/yr. Savings (10
improve) Transportation 240 B 24
B Sub-sector Energy cost/yr. Savings
(10 improve) garbage trucks 1.1 B 110
M buses 1.3 B 130 M passenger cars 100
B 10,000 M
Each 10 improvement in the efficiency of
passenger cars would save 10 Billion/year
GOAL 2 Develop fluid power hybrid vehicular
technologies that make passenger cars highly
efficient and have high performance.
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Energy Savings in Transportation via Fluid Power

• Hydraulic launch assist (HLA)
• Parallel hybrid
• Regenerates 80 braking energy
• 30 fuel saving
• Significant reduction in emissions (50 of NOx,
  30 CO2)
• 280KW power 380kJ energy

HLA on a class 3 Ford F350 truck

• Weighs 250kg
• Occupies 200 Liters
• Too heavy and too large for passenger cars

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Electric versus Hydraulic Hybrid Vehicles
FORD Explorer Hydraulic Hybrid
TOYOTA Highlander Electric Hybrid

• Fuel economy
• 33 (city) / 28 (highway) MPG
• Net weight increase
• 497 lb
• Cost Increase
• 7430

• Fuel economy
• 33 (city) / 22 (highway) MPG
• Net weight increase
• 125 lb
• Cost Increase
• 600

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EPA UPS Hydraulic Hybrid Delivery Vehicle Program
70 percent better fuel efficiency (urban
driving) 40 lower CO2 emissions 1000 gallons of
fuel saved per vehicle annually 50,000 lifetime
savings per vehicle
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Current Technology

• Battery-electric motor combination is too heavy
• Fluid power has high intrinsic power density
• However, overall system is not portable or
  un-tethered.

Apply Fluid Power
GOAL 3 Fluid power that is portable wearable
untethered autonomous capable of operating for
long periods without external energy sources.
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Monopropellant as Energy Source

• Integrated fuel cartridge and catalyst pack
  produces gas on-demand for gas actuators
• Similar to CO2 cartridge, but order of magnitude
  greater energy
• Significantly higher energy density than NiMH
  batteries (depending on concentration)
• Nonflammable
• Insensitive to shock
• Safe reaction products (steam and oxygen)

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Energetic Comparison
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The Challenge 40 of Americans over 65 have
mobility impairments. There are no portable
powered devices to help them.
The Goal People with mobility impairment will be
assisted by powerful, portable devices that are
clean, quiet and safe.
The Solution Compact and Efficient Fluid Power
National Institute on Disability and
Rehabilitation Research (NIDRR)
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The Challenge State of the art humanoid robots
(Honda P3) can only operate for 20 minutes
without doing any useful work, but the market for
service robots is estimated to worth 10 billion
in a decade (Japan Gov. Report, March, 2005)
Woody Allen as Domesticon in Sleeper, 1973

• The Goal Everyone will be helped by robots. The
  robots will be intelligent and autonomous, but
  also powerful, untethered, quiet, safe and clean.

Honda P3 Robot
The Solution Compact and Efficient Fluid Power
R2D2 and C3PO in Star Wars, 1977
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Barriers to Acceptability

• Barriers to the more widespread acceptance of
  fluid power
• 1. Leaky
• 2. Noisy
• 3. Unsafe
• 4. Difficult to use (slow, imprecise or
  non-intuitive)
• This prevents the more widespread use of fluid
  power.

GOAL4 Fluid power that is ubiquitous since it
is leak proof, quiet, safe and easy to use.
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• New Applications and New Industries
• Products rescue robots, hazardous materials
  manipulators, space and underwater robots,
  service robots, medical and rehabilitation
  devices, wearable and compact tools for home and
  industry

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Research Activity
The History of Fluid Power Research
USA
Asia
Europe
1940 1950 1960 1970 1980 1990 2000 2010 2020
1969 Bath, Aachen Fluid Power Centers Formed
2001 1st NFPAIndustry/University Summit
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ERC in Compact and Efficient Fluid Power Lead
University University of Minnesota Core
Universities University of Illinois
Urbana-Champaign, Georgia Institute of
Technology, Purdue University, Vanderbilt
University Outreach Universities Milwaukee
School of Engineering, North Carolina AT State
University (HBCU). Outreach Institutions
National Fluid Power Association, Project Lead
the Way, Science Museum of Minnesota.
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• Resources of the Center
• Best in fluid power in the country.
• Nationally Ranked in engineering, mechanical
  engineering and related disciplines.
• World-class research universities.
• Comprehensive universities with opportunities to
  tap into other expertise as the center evolves
  (medical schools, science departments,
  specialized facilities, business schools, etc.)

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ERC Organization
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Thrust Areas Efficiency Thrust is needed to
reduce our Nations dependence on imported fossil
fuels and benefit the environment. The energy
savings pay for the center many times over.
Compactness Thrust is needed to migrate fluid
power technology to human scale devices opening
up large opportunities for novel applications.
This will create entire new businesses and
increase the well-being of humanity. Effectiveness
Thrust is needed to realize the ultimate vision
of fluid power that is easy to use, clean and
safe. No one will use fluid power in the new
applications unless these problems are solved.
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ERC testbeds
TB1 Excavator
TB2 Injection molding machine
Existing FP applications
TB3 small Urban Vehicle (sUV)
TB5 FP assisted hand tools
FP enabled breakthroughs in transportation
TB4 Compact Rescue Crawler
TB6 FP assisted orthoses prostheses
Reduced or delayed funding
New industries applications
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Three level diagram
Environment specifications
Engineered

Reduced fuel consumption
TB
-
3
TB
-
4
Systems and
Testbeds

Regeneration in cyclic ops.
TB
-
5
Small urban
Rescue

Tether
-
less operation
Hand
Vehicle
Crawler

Intuitive human interface
Tools

Compact and light weight
TB
-
2

Quiet and leak free operation
Injection Molding
TB
-
6
TB
-
1
Machine
Orthosis
Excavator
System
H/W S/W
Control
integration
Energy
Compact
Compact/
Compact, efficient
Compact
-
Regeneration
light weight
pumps, motors,
power supply
energy storage
scheme
components
transformers
Cad/Cam
Throttle
-
less
Leakless
for fluid power
Enabling
Compact, high
controllable
seals
integration/
Displ
.
Human/
energy density
Technology
components
optimization
Control
Noise/
Vib
machine
storage
control
interface
Compact,
Light weight
Low loss, high
Alternate
efficient
pressure
components
efficient FP
Improved
power supply
components
configurations
filtering
Knowledge
Multi
-
scale
Engineered fluids
Chemofluidic
Functionally graded
simulation
base
actuation
materials
Dynamic
Noise
scaling
Nanotube additives
Human
Open or
cavitating flow
factors
Phase change
prediction
On/off valve
energy storage
Free
-
piston
drag
Seal design
engine comp.
Tribology
control configs
reduction
Compactness
Effectiveness thrust
thrust
Efficiency thrust
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Research integrates into Test-bed
2A Vane motor/pump
2C New accumulator configuration
Structural integrated accumulator
TB3 sUV
2E Integration/Optimization 2D Composite and
functionally graded material
3B/3D Noise and leakage
TB1 and TB2
1B/1A Low friction surface 1C Biomimetic drag
reduction
C E controllable pump/motor

• Integrates results from 10 projects across all 3
  thrusts.
• Involves 9 PIs from all partnering institutions

1E On/off valve based control
Implementation with current technology
New technologies
1A Throttle-less Control design
Year 10
Year 5
Year 0
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Multi-disciplinary Teams acoustics (Cunefare,
Mongeau) biomedical engineering (Durfee,
Goldfarb, Hsiao-Wecksler)chemistry (Kaltchev,
Michael) computer-aided design (Ivantysynova,
Paredis) computer science (Paredis) education
(McCary-Henderson) engineering design (Barth,
Book, Durfee, Goldfarb, Ivantysynova) fluid
mechanics (Frankel, Loth) fluid power (everyone)
human factors (Book, Durfee, Jiang, Mountjoy,
Park) internal combustion engines (Kittleson)
materials (Gervasi, Mantell, Stelson)
manufacturing (Gervasi, Mantell, Stelson) MEMS
(Werely) system dynamics and control (Alleyne,
Barth, Book, Durfee, Goldfarb, Li, Lumkes,
Stelson)tribology (Bair, Ivantysynova, Michael,
Salant) New research initiatives will involve
collaborators from other fields available in the
participating universities.
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Faculty Recruiting

• U of M search is underway, interviews begin in
  December
• Purdue posted ad in October
• Vanderbilt in process of interviewing
  candidates
• MSOE hired Paul Michael, Fluids Expert
• UIUC one in place by year 3, another by year 5

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Thrust area 1 Efficiency

• Efficient system configurations
• 1A. Throttle-less control and regeneration
• 1E. On/off valve concepts for energy
  transformation and control
• 1F. Biomimetic approach for distributed fluid
  pressure generation, energy storage and control
• Efficient components
• 1B. EHD effects for adaptive surfaces for pumps
  and motors
• 1C. Microactuators for active modification of
  surface topology in lubrication gaps
• 1D. Drag reduction via biomimetic nano-surface
  features
• 1G. Engineered Fluids
• Red Increased funding Blue Decreased or
  delayed funding

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Thrust area 2 Compactness

• Compact power source
• 2A. Chemo-fluidic hydraulic actuators
• 2B. Free-piston engine compressor
• Compact energy storage
• 2C. Compact energy storage
• Materials
• 2D. High pressure, light weight components using
  engineered materials
• Scaling and Integration
• 2E. Component integration for fluid power systems
• 2F. Dynamically scalable fluid power systems

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Thrust area 3 Effectiveness

• Human factors
• 3A. Human factors and haptic interfaces for fluid
  power systems
• Noise vibration and cavitation
• 3B. Noise reduction in fluid power systems
• 3C. CFD simulation of cavitating flows
• Tribology
• 3D. Leakage reduction in fluid power systems
• 3E. Prevention and management of contaminants
• Red Increased funding Blue Decreased or
  delayed funding

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Equipment and Infrastructure Primary (28,000
ft2) Fluid Power Control Laboratories (UM),
Fluid Power and Motion Control Lab (GT), MAHA
Fluid Power Lab (PU), Center for Intelligent
Mechatronics (VU), Caterpillar Electromechanical
Systems Lab (UIUC), Fluid Power Institute
(MSOE). Supporting Center for Diesel Research
(UM), Composites Laboratory (UM), Nanofabrication
Center (UM), Materials Research Science and
Engineering Center (UM), Center for
Transportation Studies (UM), Integrated Acoustics
Lab (GT), Rapid Prototyping and Manufacturing
Institute (GT), Tribology Lab (GT), Microfluidics
Lab (PU), Multi-scale Manufacturing Center (PU),
Human Dynamics and Control Lab (UIUC), Institute
for Human Machine Studies (NCAT), Rapid
Prototyping Center (MSOE), Nanotechnology Center
(MSOE)
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(No Transcript)
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K-100 Learning

• General Public Of All Ages
• Interactive exhibit
• Youth education program (K-12)

awareness
lifelong learning

• Undergraduate
• Research
• Lab courses
• Lab modules
• Internships
• Design

• Junior High
• Study unit
• Lab module

• Industry
• Short courses
• Labs
• Publications

• High School
• Pre-engineering courses
• Lab module
• RET

• Graduate
• Research Fellows
• Courses
• Internships
• International Exchange

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Student Diversity Strategy
North Carolina AT State University (LSAMP)
Georgia Tech (AGEP)

• 2nd in nation, engineering Ph.D.s to African
  Americans
• 8th in nation, engineering Ph.D.s to Hispanic
  Americans
• 3rd in nation, engineering Ph.D.s to
  underrepresented minorities
• Participating in research side of ERC, Thrusts
  1-3
• AGEP with Emory, Spelman, Morehouse

• Public land grant university
• Historically Black College and University (HBCU),
  located in Greensboro, North Carolina
• Leading producer of African-American engineers in
  the nation. (B.S., Ph.D.)
• Leading producer of female engineers in the
  nation (B.S.)
• Participating in research side of ERC, Thrust 3

Other Partners

• LSAMP (Vanderbilt, Purdue)
• AGEP (NCAT, Purdue)
• Tribal Colleges (4 TCUPs in WI and MN)

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Five Year Cost Sharing
Industry (in kind)
0.66M 3.1
Industry (cash)
3.09M 14.2
University cost share
2.99M 13.8
NSF
14.97M68.9
Total Funding 21.71 Million
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Industry Members
AAA Products International   Air
Logic Aladco Bimba Manufacturing Company Bosch
Rexroth Corp. Caterpillar Inc. John Deere
CompanyDelta Computer Systems Deltrol Fluid
Products Donaldson Company Eaton
Corporation Enfield Technologies Festo
Corporation Fluid Power Educational
Foundation Gates Corporation Häglunds Drives
Inc. Haldex Hydraulics Corporation HECO Gear,
Inc. Hedland Flow Meters High Country Tek HUSCO
International, Inc. HYDACHydraquipINA USA Corp.
Schaeffler Group Kepner Products LatchTool Linde
Hydraulics Corp.G.W. Lisk Co., Inc. Main
Manufacturing Products, Inc.
Master Pneumatic-Detroit, Inc.Mead Fluid
Dynamics MICO, Inc. Moog Inc. MTS Systems
Corp. National Fluid Power AssociationNational
InstrumentsNational Tube Supply
Co. NORGREN Parker Hannifin Corporation PHD,
Inc.PIAB Vacuum Products Poclain Hydraulics,
Inc. Prince Manufacturing Corporation Quality
Control Corporation R.T. Dygert
International Ralph Rivera RB Royal Industries,
Inc. RohMax USA, Inc. ROSS Controls Sauer-Danfoss
Schroeder Industries Shell Oil Simmetrix Sterling
Hydraulics, Inc. Sun Hydraulics
Corporation SunSource Tennant Company The Toro
Company Veljan Hydrair Private Limited
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Master Pneumatic
National Tube Supply Company
HIGH COUNTRY TEK
Ralph Rivera
Member of the Schaeffler Group
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Fluid Power Industry Supply Chain
Suppliers
National Tube, RohMax, Shell Oil
Bosch-Rexroth, Donaldson, Eaton, Festo, Husco,
Moog, Parker-Hannifin, Sauer-Danfoss, and many
others
Component System Mfg.
Distributers
Sunsource, RT Dygert
Customers
Caterpillar, Deere, MTS, Tennant, Toro
Education Service
NFPA, Universities Colleges,Trade Press,
Training,
End Users
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Conclusion
Efficiency Energy and Environment Compact
Transformation Clean, quiet, safe, easy to use
Required Education Next generation
leaders Industry support Implementation