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CCEFP Webinar 2-22-2016

Project 16MA1: Efficient, Integrated,

Freeform Flexible Hydraulic Actuators

Jonathon Slightam, Research AssistantMarquette University

Advisor: Dr. Mark NagurkaPhoto

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Marquette’s Research Team

• Dr. Mark L. Nagurka.

– B.S and M.S. from Penn, Ph.D. from MIT.

– Taught at CMU and MU for 20 years.

– Worked with Henry Paynter.

• Jonathon E. Slightam

– PhD. Student and research assistant at MU.

– Worked on CCEFP projects for B.S. and M.Sc. at MSOE.

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Work on Flexible Actuation

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Overview

• Project goals.

• Project objectives and milestones.

• Significant impact.

• Background.

• Current results: Modeling/testing preparation.

• Future work.

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Project IntroductionGoal of research is to advance state-of-the-art in hydraulic actuator technology using flexible fluidic actuators and additive manufacturing (AM).

– Increase actuation specific power.

– Decrease system weight using AM.

– Improve efficiency through optimal control.

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Research Motivation

• Decrease the overall energy consumption in fluid power industry.

– 2-2.9 Quads consumed by fluid power in U.S.• 1 Quad = 1 Quadrillion BTUs.

– Total energy consumption in U.S. is 100 Quads per year.

– 310-380 MMT CO2 produced by fluid power in U.S.

– Fluid power is 2-3% of U.S. energy demands.

– System efficiencies ranging from 9% to 60%.

• Reducing energy consumption in fluid power is critical to CCEFP’s strategic plan.

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Research Objectives• Increase power density of hydraulic actuators to 25kW/kg or

greater.

• Utilize AM technologies to reduce energy consumption in hydraulic machinery by 30%.

• Reduce energy consumption by 5% using optimal control techniques.

Outcomes (major milestones):

(Year 1) (Year 2)

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Significant Impact

• Reductions in system weight by 30% result in a similar reduction in energy consumption. If adopted by entire industry, energy consumption could be cut by 0.85 Quads.

• Model-based energy optimal trajectory planners could reduce energy consumption by as much as 0.3 Quads and $5.6 billion/year.

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Background• Flexible fluidic actuators

– Hydraulic artificial muscles.

• Additive manufacturing

– Optimization and fluid power component integration.

– Saving energy by weight reduction.

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Flexible Fluidic ActuatorsFlexible fluidic actuators transmit mechanical power through large deformations of elastic or hyperelastic membranes by an energized fluid.

Prolate (contract/pull)Oblate (expand/push) Helical (Twist)

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Hydraulic Artificial Muscles

• Efficiencies near 80%.

• Performance limitations unknown.

– Devices reported operate at low pressure (<4MPa or <580psi, max. is 7 MPa ~ 1000psi).

• Reduced actuator weight = reduced machine weight.

Table 1: Generalized Performance of Actuation Technology.

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Additive Manufacturing

AM or freeform fabrication is an additive layer based manufacturing technology (SLS shown).

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Additive Manufacturing

Freeform fabrication allows for integrated components, fluidic conduits, actuators, and optimal layouts and topologies.

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Additive Manufacturing• Can reduce weight as high as 80%.

• Can reduce energy consumption by as high as 42%.

• Can increase compactness as high as 90%.

• More efficient fluid flow paths in manifolds and conduits.

• Consistent trend will emerge with more case studies.

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Current Progress

• Testing preparation

• Modeling

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Hydraulic Circuit 1. Motor.

2. Fixed displacement pump.

3. Bladder style accumulator.

4. Pressure relief valve.

5. Check valve(s).

6. Flow control valve.

7. Hydraulic artificial muscle.

8. Tank.

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Test stand

• Development and fabrication of test stand.

– Hydraulic circuit design.

– Component spec. through modeling and simulation.

– CAD and fabrication.

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Test stand

• Test stand specifications

– Capable of 14 MPa (twice what is reported in the literature).

– Short bursts of 15 kW and sustainable power of 1.5 kW.

– Redundantly contained test cell.

– Allows for quasi-static and position control experiments.

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System ModelLumped parameter modeling of hydraulic artificial muscle system.

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Actuator Model

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Future work

• Fabrication of prototypes.

• Finalize test stand.

• Test hydraulic artificial muscles

– Specific power.

– Static and Dynamic behavior.

• Controls

• Implementation into hydraulic hand tool.

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Questions and Comments

Jonathon E. Slightam

jonathon.slightam@marquette.edu

Dr. Mark L. Nagurka

mark.nagurka@marquette.edu

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