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Switch-mode hydraulic circuits are a theoretically efficient, compact, fast responding, and inexpensive control option. Despite the many potential benefits of switch-mode hydraulic circuits, the control method suffers from large energy losses during transitions of the high-speed valve due to throttling and fluid compressibility. Rannow and Li previously proposed utilizing soft switching to minimize the throttling energy loss (Rannow and Li, "Soft Switching Approach to Reducing Transition Losses in On/Off Hydraulic Valve," J. Dyn. Syst., Measure. Control (in press)). A major challenge of this approach is a locking soft switch that releases quickly and with precise timing, while under load. In this paper, a novel soft switch locking mechanism is presented that utilizes the pressure signal in the switched volume to trigger the release. A dynamic model is developed of three unique soft switch circuits and two control circuits that create a virtually variable displacement pump. The model is used to perform a grid search optimization of the soft switch parameters for the three circuits. The three soft switch circuits reduce the throttling and compressibility energy losses between 49% and 66% compared with the control circuit. The simulation results demonstrated that the soft switch circuits perform as expected for duty cycles and pressures below the design conditions. At higher duty cycles and pressures, the short time the circuit is connected to tank prevented the soft switches from resetting between cycles, preventing proper function. This novel lock and release soft switch mechanism enables soft switching in switch-mode hydraulic circuits, which significantly reduces throttling and compressibility energy losses during valve transitions. Lower losses during valve transition allow the use of slower switching valves, lowering energy consumption, and cost. [ABSTRACT FROM AUTHOR]

Fluid compressibility has a major influence on the efficiency of switch-mode hydraulic circuits due to the release of energy stored in fluid compression during each switching cycle and the increased flow rate through the high-speed valve during transition events. Multiple models existing in the literature for fluid bulk modulus, the inverse of the com-pressibility, are reviewed and compared with regards to their applicability to a switch-mode circuit. In this work, a computational model is constructed of the primary energy losses in a generic switch-mode hydraulic circuit with emphasis on losses created by fluid compressibility. The model is used in a computational experiment where the system pres-sure, switched volume, and fraction of air entrained in the hydraulic fluid are varied through multiple levels. The computational experiments resulted in switch-mode circuit volumetric efficiencies that ranged from 51% to 95%. The dominant energy loss is due to throttling through the ports of the high-speed valve during valve transition events. The throttling losses increase with the fraction of entrained air and the volume of fluid experi-encing pressure fluctuations, with a smaller overall influence seen as a result of the sys-tem pressure. The results of the computational experiment indicate that to achieve high efficiency in switch-mode hydraulic circuits, it is critical to minimize both the entrained air in the hydraulic fluid and the fluid volume beh\'een the high-speed valve and the pump, motor, or actuator. These computational results are compared with experimental results in Part II of this two part paper series. [ABSTRACT FROM AUTHOR]

In this article, the author presents experimental work with a generic switch-mode hydraulic circuit. It mentions that the experiment aims to validate a previously presented computational model, emphasizing the energy loss due to fluid compressibility. It includes that calculated volumetric efficiency from experimental works ranged from to 61 percent to 75 percent, with efficiency increasing with decreased levels of entrained air, system pressure, and switched volume.

A challenge in realizing switch-mode hydraulic circuits is the need for a high-speed valve with fast transition time and high switching frequency. The work presented includes the design and modeling of a suitable valve and experimental demonstration of the prototype in a hydraulic boost converter. The design consists of two spools driven by crank-sliders, designed for 120 Hz maximum switching frequency at a flow rate of 22.7 lpm. The fully open throttling loss is designed for <2% of the rated pressure of 34.5 MPa. The transition time is less than 5% (0.42 ms at 120 Hz) of the total cycle and the duty cycle is adjustable from 0 to 1. Leakage and viscous friction losses in the design are less than 2% of the rated hydraulic energy per cycle. The experimental results agreed well with the model resulting in a 3% variation in transition time. The use of the high-speed valve in a pressure boosts converter demonstrated boost ratio capabilities of 1.08-2.06. [ABSTRACT FROM AUTHOR]