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RESEARCH PRODUCT

A method for smoothly disengaging the load-holding valves of energy-efficient electro-hydraulic systems

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A novel self-contained, electro-hydraulic cylinder drive capable of passive load-holding, four-quadrant operations, and energy recovery was presented recently and implemented successfully. This solution improved greatly the energy efficiency and motion control in comparison to state-of-the-art, valve-controlled systems typically used in mobile or offshore applications. The passive load-holding function was realized by two pilot-operated check valves placed on the cylinder ports, where their pilot pressure is selected by a dedicated on/off electro valve. These valves can maintain the actuator position without consuming energy, as demonstrated on a single-boom crane. However, a reduced drop of about 1 mm was observed in the actuator position when the load-holding valves are disengaged to enable the piston motion using closed-loop position control. Such a sudden variation in the piston position that is triggered by switching the load-holding valves can increase up to 4 mm when open-loop position control is chosen. For these reasons, this research paper proposes an improved control strategy for disengaging the passive load-holding functionality smoothly (i.e., by removing this unwanted drop of the piston). A two-step pressure control strategy is used to switch the pilot-operated check valves. The proposed experimental validation of this method eliminates the piston position’s drop highlighted before and improves the motion control, mainly when operating the crane in open-loop. Theses outcomes benefit those systems where the kinematics amplifies the piston motion significantly (e.g., in aerial platforms) increasing, therefore, the operational safety. The authors acknowledge the funding through the Norwegian Research Council projects Motion Lab (245717/F50) and SFI Offshore Mechatronics (237896).