A double acting cylinder operation has been fully monitored in its key functional parameters, focused on characterization of end-of-stroke cushioning and starting phases. Being the cylinder performance reliant in the piston constructive geometry, the number and location of piston circumferential grooves is a significant parameter affecting the internal cushioning system performance. An eddy current displacement sensor assembled in the piston allows assessment of piston radial displacement inside the cylinder tube, which is directly related with the studied operating phases. Due to such 3D displacements, the piston becomes as an active and self-adjusting element along the functional cycle of the cylinder. Mechanical joints orientation and operating pressure are also relevant parameters affecting piston radial displacement and, thus, the cushioning and starting performance. Computational Fluid Dynamics (CFD) results confirm the observed functional role of the perimeter grooves; the flow and pressure distributions, where develops a significant radial force, are also in accordance with the registered radial displacement.

Abstract:Cushioning is an important aspect in hydraulic cylinder performance. The piston has to be decelerated before it strikes the end cap in order to avoid stresses in the cylinder components and reduce vibration that can be transmitted to the machine. One of the least-studied methods is internal cushioning by grooves in the piston. In this method, the flow is throttled with adequately designed grooves when the piston reaches the outlet port position. The purpose of the present work is to present a method to estimate the pressure-drop coefficients for a certain design of piston grooves in order to provide a model to develop a dynamic system simulation of the cushion system. The method is based on a computational fluid dynamic simulation of flow through piston grooves to the outlet port for each piston's static position. The results are compared with experimental measurements, and a correction, based on Reynolds number, is proposed. Good agreement, below 16%, was obtained for all the positions but particularly for the last grooves, for which the numerical result's deviation to the experimental measurements was less than 10%. In general, the numerical simulation tended to underestimate the pressure drop for the first grooves and overestimate the calculation for the last grooves.

The internal cushioning systems of hydraulic linear actuators avoid mechanical shocks at the end of their stroke. The design where the piston with perimeter grooves regulates the flow by standing in front of the outlet port has been investigated. First, a bond graph dynamic model has been developed, including the flow throughout the internal cushion design, characterized in detail by computational fluid-dynamic simulation. Following this, the radial movement of the piston and the fluid-dynamic coefficients, experimentally validated, are integrated into the dynamic model. The registered radial movement is in coherence with the significant drag force estimated in the CFD simulation, generated by the flow through the grooves, where the laminar flow regime predominates. Ultimately, the model aims to predict the behavior of the cushioning during the movement of the arm of an excavator. The analytical model developed predicts the performance of the cushioning system, in coherence with empirical results. There is an optimal behavior, highly influenced by the mechanical stress conditions of the system, subject to a compromise between an increasing section of the grooves and an optimization of the radial gap.

The indirect calculation from acceleration of transversal displacement of the piston inside the body of a double effect linear hydraulic cylinder during its operating cycle is assessed. Currently an extensive effort exists in the improvement of the mechanical and electronic design of the highly sophisticated MEMS accelerometers. Nevertheless, the predictable presence of measurement errors in the current commercial accelerometers is the main origin of velocity and displacement measurement deviations during integration of the acceleration. A bond graph numerical simulation model of the electromechanical system has been developed in order to forecast the effect of several measurement errors in the use of low cost two axes accelerometers. The level of influence is assessed using quality indicators and visual signal evaluation, for both simulations and experimental results. The obtained displacements results are highly influenced by the diverse dynamic characteristics of each measuring axis. The small measuring errors of a simulated extremely high performance sensor generate only moderate effects in longitudinal displacement but deep deviations in the reconstruction of piston transversal movements. The bias error has been identified as the source of the higher deviations of displacement results; although, its consequences can be easily corrected.