Introduction

The dynamic analysis is the important stage at designing of hydraulic drives and
transmissions of various machines and mechanisms (cars, self-propelled chassis, tractors,
cranes, tractors, loaders, excavators, scrapers, machine tools, hydraulic stands, etc.) and
allows to simulate long before creation of a pre-production model working processes and
to obtain necessary data about dynamic properties of hydraulic system and features of
passing of working processes, to pay attention to presence of weak places in hydraulic
system, and before carrying out of tests to carry out optimization of the design decision
on a basis of results of mathematical simulation and the alternative analysis.

Mathematical simulation of various modern technical systems of the certain class

(mechanical, hydraulic, electric, etc.) is connected with construction of the models
providing the formalized description of any such system of arbitrary structure.

For construction of formal dynamic model of hydraulic system as a whole the method
based on representation of system in the form of finite element-node structure is used. In
a basis of such approach the idea of a method of finite elements lays when the complex
system on a configuration can be divided conditionally into separate functional elements
which mathematical description is known and for which within the limits of considered
system it is possible to define unequivocally conditions of communications of these
elements with each other (input output). Then for the description of system as a whole it
is enough to specify a name (identifier of type) of element, to number its nodes on an
input and an output, to give necessary physical, geometrical and design data (constants)
and to write down the equations, transforming variables on an input of an element in
variables on an output.

As such base elements in hydraulic systems can be: pump, hydraulic motor, hydraulic
cylinder, direct action valve, indirect action valve, local resistance (throttle), pipeline
(including, deadlock site of pipeline or cavity), tee (divider or adder of flows), power
regulator, hydro pneumatic or spring accumulator, directional control valve, pilot
operated check valve, diesel engine with centrifugal regulator, wheel carrier, linear
dynamic links of automatic control systems (ACS).

Then the structure of any hydraulic circuit can be described by means of identification of
elements, numbering of nodes (points of connection of elements in the circuit by a
principle input output) and forming on a basis of it matrices of communications
describing the circuit structure (topology). Thus, for simulation of dynamic processes in
hydraulic systems of arbitrary structure the following things are necessary:

algorithm of the structural description of arbitrary hydraulic circuits;

library of base hydraulic elements and their mathematical models;

 ordering of input data, and a way of their forming and preparation;

algorithm of automatic forming of system of equations describing the hydraulic circuit

of arbitrary structure as a whole;

method of solving of the generated system of equations;

program realization of dynamic calculation of any hydraulic circuits;

way of representation and analysis of the received results.

The program analyzes the input information and depending on set of elements and
structures of the investigated hydraulic circuit chooses from library of base hydraulic
elements and their mathematical models the necessary equations, forming the general
mathematical model of hydraulic system and solving it at the given external influences.

Structure description of arbitrary hydraulic circuits

The analysis of the various hydraulic systems applied in various mobile machines
(automobiles, road, building, digging-transport machines, excavators, tractors, etc.),
shows, that there is a finite set of base hydraulic elements by means of which it is
possible to synthesize practically any circuit of hydraulic drive. These elements are:
pump, hydraulic motor, hydraulic cylinder, valves of direct and indirect action, throttle
(local resistance), pipeline (including, a deadlock site of pipeline or a cavity), tee (divider
or adder of flows), power regulator, hydraulic accumulator, pilot operated check valve,
directional control valve, diesel engine with a centrifugal regulator, wheel carrier,
elements of automatic control systems (ACS).

Calculation of any hydraulic circuit is reduced to definition of variable pressures, flows,

speeds and positions of mobile parts in points of connection of hydraulic elements
nodes of the circuit. Thus of the same node can be simultaneously an output of one
element and an input of another.

Any hydraulic circuit can be considered as set of elements making it and nodes points
of connection of these elements. Each element of the hydraulic circuit, except directional
control valve, it is possible to present in the form of a three-node element with nodes i
(input), j (output) and k (control or transformation of energy), connecting it with other
elements of the circuit (Fig. 1).
 Fig. 1. Base hydraulic elements and their nodes

a pump, b hydraulic motor, c hydraulic cylinder, d hydraulic accumulator, e

valve of direct action, f valve of indirect action, g pipeline, h deadlock site of
pipeline (cavity), i throttle (local resistance), j tee, k power regulator, l directional
control valve, m pilot operated check valve, n diesel engine with a centrifugal
regulator, o wheel carrier, p linear dynamic link of automatic control system (ACS).

The input and output of an element are defined by the accepted direction of flow of
working liquid. At change of a direction of flow the sign of the corresponding parameters
describing work of an element (pressure difference, flow of a liquid, etc.) varies.
According to it the following classification of nodes of base hydraulic elements is
accepted. Here diesel engine as the most widespread type of drive engine in mobile
machines is presented also.
 Table 1. Classification of base hydraulic elements nodes

Element Node i Node j Node k

Pump Input Output Taking power away

(sucking pipeline) (pressure head pipeline) engine (shaft)
Hydraulic motor Input Output Transfer of power to
(pressure head pipeline) (drain pipeline) working mechanism
(shaft)
Hydraulic cylinder Input Output Transfer of power to
(pressure head cavity) (drain cavity) working mechanism
(cylinder rod)
Valve of direct action Input Displacement of locking-
(pressure head pipeline) (drain pipeline) regulating element
Hydraulic accumulator Input Output Displacement of piston
(pressure head cavity) (gas cavity or spring (membrane)
cavity)
Pipeline Input Output -
Deadlock site of pipeline Input Output -
(cavity) (deadlock end of
pipeline)
Throttle Input Output -
Tee:
divider of flow Input Output Output

adder of flows Input Input Output

Valve of indirect action

1-st cascade Input Output Displacement of locking-

(auxiliary (pressure head pipeline) (drain pipeline) regulating element of
valve) auxiliary valve
Input Output Displacement of locking-
2-nd cascade (pressure head pipeline, (drain pipeline, node s), regulating element of base
(base valve) r) may be: s = j valve, node t
Power regulator Input Input Regulator piston
(the 1-st pipeline) (the 2-nd pipeline) displacement
Pilot operated check
valve: Input Output Pusher displacement,
pusher (pressure head pipeline, (feed pipeline, node t
node r) node s)
Input Output
valve (pressure head pipeline) (drain pipeline) Valve displacement

Diesel engine with a - Output Diesel regulator muff

centrifugal regulator (engine shaft) displacement
Wheel carrier Input Output Machine case
(wheel axis) (contact point of wheel
with road)
Link of automatic Input Output Input
control system (ACS) (for adder only)

According to the reduced classification each type of element has received a special name
the identifier allowing at forming of the general model of hydraulic system to choose in
library of mathematical models of hydraulic elements the necessary group of the
equations, namely: mathematical model of the given type element. Following identifiers
of base hydraulic elements have been chosen: PUMP (pump), MOTOR (hydraulic
motor), CYLINDER (hydraulic cylinder), PIPE (pipeline), VALVE (valve of direct
action), etc.

According to the entered identification each element e of hydraulic circuit concerns to the
certain type with corresponding it nodes i , j , k. Then the structure of any hydraulic
circuit after numbering its all nodes is described by the following matrix S :

S= , (1)

where e1 , . , eN elements of hydraulic circuit, N their number.

The identifier em defines the mathematical model corresponding an element, and numbers
of nodes im , jm , km establishments of conditions of communication of elements with
each other serve for indexation of variables and, as consequence. For example, if the
output of an element em is at the same time an input of an element en it is obvious, that jm
= in and therefore, variables on an output em and on an input en coincide, i.e. the
corresponding condition of communication takes place.

As a result of such description of structure of the circuit those equations by which

elements entering into the circuit are described will be chosen from the general library of
mathematical models of elements, and indexation of variables entering into the equations
(a condition of communications), will be established on a basis of numbering nodes of
elements specified in matrix S.

The unique element which is dropping out of the general concept of a three-node element
is directional control valve as the number of nodes adjoining them can be more than
three. Therefore well consider directional control valve as set of local resistances
possible connections of nodes of a spool (Fig. 1l). Then its structure can be described by
forming of additional matrix U:

U= (2)

where i1 , j1 , i2 , j2 , ... , iL , jL numbers of nodes of input and output of connections

1, 2, ... , L of directional control valve spool, L number of connections.

Thus, the description of structure (topology) of any hydraulic circuit for carrying out of
dynamic analysis is formalized by:

- drawings of nodes on simplified circuit points of connection of elements, and

numbering of nodes;

- forming of structural matrix S on a basis of identification of base elements and

numberings of their nodes in the circuit;

- forming of corresponding number of matrices U at presence of directional control

valves in the circuit.

Library of hydraulic elements and their mathematical models

The kind of the equations of base hydraulic elements depends, generally, on the
assumptions accepted at decision of specific problems. As in this case we consider
methods of computer-aided dynamic calculation, described by two basic features:
automatic forming of mathematical model by a choice of necessary equations from the
general library of mathematical models and construction on a basis of it programs of
mass using oriented to application for hydraulic systems of arbitrary kind, it was
necessary to choose from the big number of available models of elements the most
common models, comprehensible to the decision as more as possible the broad audience
of problems. Therefore for some hydraulic elements described with a various degree of
detailed elaboration (pipeline, local resistance), the special researches [1] have been
carried out by the author. The purpose of these researches was the comparative analysis
of applied models for estimation of a degree of their adequacy at various external
influences and parameters. As a result for mathematical description of hydraulic elements
chosen as base ones the mathematical models reduced below have been accepted into
which the following designations are entered: pressure; Q flow; M torque
moment. Indexation of variables is made according to numbers of nodes in which the
given variable (Fig. 1) operates.

The library of equations of hydraulic elements reduced below basically can suppose their
various mathematical descriptions under condition of preservation of the concept of a
three-node element.

Pump. For the pump description it is enough to write down the equation of moments on a
shaft (node k) and equations of flows in input (node i) and output (node j) in view of
volumetric losses. Thus non-uniformity of the pump flow owing to kinematic features
and compressibility of working liquid in sucking and pressure head cavities is not
considered. In view of the accepted assumptions the pump mathematical model looks like
[1, 2]:

, (3)

qp maximal geometric volume of pump; f (q) parameter of regulation; 1 f (q)

1;

s angular speed of diesel engine shaft; , , coefficients of pump hydro

mechanical losses depending on angular speed, pressure, and constant of hydro
mechanical losses; ue transfer number of gear between an engine and a pump; klea
coefficient of pump volumetric losses (leakages); for Qi , pi the sign "plus" is accepted,
for Qj , pj the sign "minus". Values , , , klea get out under the catalogue or from
passport characteristics of mechanical and volumetric efficiency of the certain standard
size pump. The hydro mechanical losses depending on pressure, are calculated on the
module for an opportunity of consideration of brake modes and flow reversing (when f
(q)<0).

Hydraulic motor. The mathematical model of hydraulic motor should to describe its
dynamics (the equation of moments in node k, resolved relatively angular acceleration
and written down in a normal form), and also the equations of flows in input (node i) and
output (node j) in view of volumetric losses. Without taking into account non-uniformity
of flow (it is similar to pump) the equations of the hydraulic motor look like [1, 2]:

(4)

where k angular speed of the hydraulic motor shaft; Jm moment of inertia of the
hydraulic motor in view of rotating masses of working mechanism; qm the hydraulic
motor maximal geometric volume; f (q) parameter of regulation; 1 f (q) 1; l
loading moment; b , b , b coefficients of hydraulic motor hydro mechanical losses
depending on angular speed, pressure, and constant of hydro mechanical losses; umech
transfer number of the working mechanism gear; klea coefficient of hydraulic motor
volumetric losses (leakages); for Qi , pi the sign "plus" is accepted, for Qj , pj the sign
"minus". As well as for a pump, values b , b , b , klea choose under the catalogue or
from passport characteristics of mechanical and volumetric efficiency of the certain
standard size hydraulic motor. Hydro mechanical losses in the equation of the moments
are written down in view of a shaft rotation direction (sign k) and opportunities of
consideration of a brake mode | pi pj |.

Hydraulic cylinder. Dynamics of hydraulic cylinder is described by the equations of

progressive motion of piston (node k) at action of pressure, external loading, forces of
friction and the equations of flows on input (node i) and output (node j) in view of
compressibility of liquid in cavities of the cylinder. On a basis of the standard assumption
about absence of leakages in hydraulic cylinder with rubber and other soft seals the
equations of the hydraulic cylinder dynamics look like [1, 2]:

(5)

where vk speed of the piston moving; mass of the hydraulic cylinder mobile parts

reduced to a rod; the piston working area in cavity I

adjoining node i (here Dc diameter of cylinder; Di diameter of rod in cavity I );

the piston working area in cavity I adjoining node j (here

Dj diameter of rod in cavity II ); h coefficient of viscous friction; R force of

friction in seals at absence of pressure; R force on the rod; the full piston stroke.

Coefficients of proportionality between pressures in cavities I (node i) and II (node j) and

force of friction in cylinder seals:

k = f (Dc + Di ) H / 2, k = f (Dc + Dj ) H / 2,

and coefficients of elasticity of cavities with working liquid:

k = (V+ z Fi ) / E , k = [V + (L z) Fj ] / E ,
where f coefficient of seal friction on the cylinder surface; H height of seal; V and
V dead volumes of cavities I and II ; E reduced volumetric module of elasticity
of a cavity with a liquid:

E= ,

here volumetric module of elasticity of working liquid; thickness of the

cylinder wall; an elasticity module of the cylinder wall material.

Hereinafter a function of dry friction f (vk) is written down for brevity in the form of R
sign vk . Actually, if to write down the equation of movement in a general view:

m = P f (vk ),

where P moving force, a function of dry friction f (vk) will be defined as follows [2]:

Such model of friction describes presence of stagnation zone at zero speed of a mobile
part, for example, at starting.

Pipeline. For description of dynamic processes in pipeline with a liquid the mathematical
model with the concentrated parameters in input (node i) and output (node j) of pipeline,
taking place at the following conditions is used:

- wave processes are not considered;

- losses of pressure on length depend on average value of flows in input and output;

- inertial component of a working liquid is not considered.

Then the mathematical model of pipeline with a liquid looks like [1, 2]:
 (7)

k coefficient of elasticity of pipeline with a liquid; coefficient of pressure

losses on length of pipeline, density of working liquid.

= ,

here d L diameter and length of pipeline; E reduced volumetric module of

elasticity of a pipeline with a liquid:

E= ,

volumetric module of elasticity of working liquid; thickness of the

pipeline wall; elasticity module of the pipeline material.

here Re = 2 | Qi + Qj | / ( d ) Reynolds's number, kinematic viscosity of a

liquid.

Deadlock site of pipeline (cavity). For a deadlock site of pipeline losses of pressure on
length can be neglected, and then its equations of dynamics become:

(8)

where coefficient of elasticity of deadlock pipeline with a liquid.

 ,

here d and L diameter and length of deadlock pipeline; E reduced volumetric

module of elasticity of a pipeline with a liquid:

E= ,

where volumetric module of elasticity of working liquid; d thickness of deadlock

pipeline wall; elasticity module of the pipeline material.

Local resistance (throttle). Flow of liquid through a throttle is connected with pressure
difference in input (node i) and output (node j) by known dependence [1, 2]:

(9)

where flow coefficient, = (here coefficient of hydraulic resistance;

throttle through passage section area.

Use of flows equation (9) often is as the reason of instability of computing process
because of aspiration to infinity of a derivative of a square root in zero (it takes place at
small differences of pressures). The equation (9) defines the flow through a throttle in
established mode of current of a liquid and, hence, does not consider inertial properties of
liquid. More precisely dependence of flow through a throttle is expressed by the
differential equation [3]:

(10)

where l length of a liquid column in local resistance; besides for brevity of records

here it is designated: .

However the equation (10) is of little use for practical use. The matter is that the length l
of a liquid column is defined not only constructive length of local resistance, but also
length of a zone of unsteady current in output of throttle ("torch"), to define which even
by experimental is very difficultly. Besides at consideration of adjustable throttle there
are difficulties of computing character connected with discontinuity of the right part of

the equation (10) at = 0. In work [1] it has been shown, that (10) without essential
errors it is possible to replace the linearized equation relative to Q with the differential
equation:

(11)

which is deprived the specified lacks and asymptotic solution of which coincides with the
solution of equation (9). Here B the parameter considering inertia of a liquid column
and depending on l and some other values ( has dimension of time).

The equations of flows for other kinds of local resistance (tees, valves, pilot operated
check valves, directional control valves) are similar to the equations (11).

Tee (divider or adder of flows). The equations of flows in tee nodes i , j , k at division
of flow look like [1, 2]:

(12)

where flow coefficient in tee branches i j , i k ; = (here

coefficients of hydraulic resistances of tee branches i j , i k ); through passage

section areas in tee nodes j and k . The equations at summation of flows are similar
(12), but have other values of flow coefficients. The assumption, that coefficients of
hydraulic resistances at change of direction of flow do not vary, is accepted.

Valves.

The direct action valve is described by equations of movement of locking-regulating

element (node k) and equations of flows (nodes i and j) [1, 2]:

(13)
where vk speed of movement of locking-regulating element; m mass of valve moving
part; Fi and Fj working areas of locking-regulating element from pressure head and
drain lines; h coefficient of viscous friction; Rfr force of dry friction; rigidity of

spring; preliminary compression of spring; stroke of locking-regulating

element; area of through passage section of throttle connected in parallel to the

valve; average diameter of throttling crack of the valve; angle of the valve
cone; parameter considering inertia of a liquid column.

These equations concern to pressure relief and check valves. The corresponding
equations for reducing valve have insignificant differences. In the equations (13) a hydro
dynamical force which essential influences only on static characteristic of valve [2] is not
considered.

The indirect action valve can be presented in the form of two elements: a basic valve with
nodes r, s, t and an auxiliary valve with nodes i, j, k. If node j is general for both valves,
i.e. s = j then mathematical model of the indirect action valve looks like [1, 2]:

(14)

where vk , zk speed and displacement of locking-regulating element of auxiliary valve;

vt , zt speed and displacement of locking-regulating element of basic valve; and

masses of moving parts of auxiliary and basic valves; working areas of

locking-regulating element of auxiliary valve from pressure head and drain lines;

working areas of locking-regulating element of basic valve from pressure

head line and cavity between the valves; h and H coefficients of viscous friction of

auxiliary and basic valves; forces of friction in auxiliary and basic

valves; and rigidity of springs of auxiliary and basic valves;

preliminary compression of springs of auxiliary and basic valves;

stroke of mobile parts of auxiliary and basic valves; G conductivity of orifice apertures

of basic valve; average diameters of throttling cracks of auxiliary and

basic valves; angles of cone of auxiliary and basic valves;

Hydraulic accumulator. For the description of dynamics of hydro pneumatic or spring

accumulator it is necessary to write down equations of piston (membrane) movement in
node k, equation of pressure in input (node i) and equation of polytropic process in a gas
cavity (node j) [1, 2]:

(15)

where mass of a mobile part of hydraulic accumulator; F = D / 4 working area

of piston; D diameter of piston; h coefficient of viscous friction; rigidity of

spring; z preliminary compression of spring; force of friction at absence of

pressure; coefficient of proportionality between force of friction and

pressure in working cavity; f coefficient of seal friction on a surface of cylinder;

seal height; V general volume of accumulator; k coefficient of elasticity of a

cavity with liquid:

k = (V+ z F)/E,

here V dead volume of cavity with liquid; E reduced volumetric module of

elasticity of cavity with liquid:

E= ,
here volumetric module of elasticity of working liquid; thickness of the

accumulator wall; module of elasticity of the accumulator wall material;

pressure of charged gas; n exponent of polytropic process; atmospheric pressure.

Power regulator is intended for maintenance of constancy of power selected from engine
pQ = const. Actually, power regulator provides a constancy of value: pf (q) = const in the

certain working range of pump. However, considering, that , where qp

is practically constant, it is possible to speak, that power regulator provides constant

selection of power from engine. The static characteristic of power regulator (Fig. 2) looks
like piecewise linear function approximating hyperbolic dependence of pump working
volume from pressure: pf (q) = const. In practice it is carried out by means of selection of
springs for the 1-st and the 2-nd branches of power regulator characteristic (accordingly,
AO and D, Fig. 2).
 Fig. 2. Static characteristic of power regulator

Then power regulator is described by the following system of equations [1, 2]:

(16)
where mass of mobile part of power regulator; coefficient considering for axial-
piston pumps the additional moment, acting to swinging unit; F working area of

plunger under pressure of each of two pipelines; force of preliminary compression

of spring; Rfr force of friction; rigidities of springs; stroke of plunger on

the 1-st branch of power regulator characteristic; h coefficient of viscous friction;

maximal stroke of power regulator plunger.

Pilot operated check valve. Pilot operated check valves are used for fixing and control
of lowering of working bodies which are being under action of external loadings, in
hydraulic systems of building machines (cranes, loaders, winches). On Fig. 3 simplified
circuit of pilot operated check valve and diagram of its connection in hydraulic system is
shown. At submission of liquid 1 in cavity under valve 3 it works as usual check valve,
passing flow of working liquid to hydraulic cylinder. At submission of liquid 1 under
piston of pusher 2 it compulsorily opens the valve, providing passage of flow through
throttle from of hydraulic cylinder at piston lowering. On the scheme indexes i , j , k
designate nodes accordingly of input, output and moving of valve, and by indexes r, s, t
nodes accordingly of input, output and moving of pusher. Pilot operated check valves
are issued in two modifications: with general drain of pusher and valve (in this case r = i)
and with separate drain (then r i ).
 Fig. 3. Pilot operated check valve and its connection in hydraulic system.

Depending on, whether there are pusher and valve in contact or not, dynamics of pilot
operated check valve is described by two various mathematical models. In the time
moment of contact occurrence when pusher starts to influence the valve, there is their
impact that leads to necessity of correction of coordinates according to existing
dependences of theory of shock systems.

At absence of contact of pusher and valve dynamics of pilot operated check valve is
described by the following system of equations [1, 2, 4]:
 (17)

where and masses of valve and pusher; working areas of

valve and pusher in input ( i, r ) and output ( j, s ); forces of friction of valve

and pusher; h coefficient of viscous friction; , z0 rigidity and preliminary

compression of spring; l and L maximal stroke of valve and pusher; flow

coefficient, diameter of crack and angle of valve cone.

At approach of pusher and valve contact, when

, (18)

and at absence of impact both bodies move in common, therefore their movement is
described by the system of equations:

(19)

where 0 clearance between pusher and valve.

The given model is incomplete as, considering great speeds and geometry of mobile parts
which contact can be considered as the central impact of elastic cores, would be incorrect
to consider, that at performance of conditions (18) the system instantly passes from
condition described by the equations (17) in condition, described by the equations (19). It
speaks about necessity of introduction of transitive shock mode model.

It is possible to apply formulas of classical hypothesis of impact to considered shock

system "pusher-valve". Let before impact body in mass of m had speed , and body in

mass of M had speed ; then speeds of these bodies after impact (accordingly

) will be equal

(20)

where coefficient of restoration.

Preliminary computations of the accepted shock model at k = 0.5 have shown, that
arising high-frequency shock fluctuations of valve concerning pusher have enough small
amplitude, and besides, as a result of their attenuation there comes such moment when
values of rebounds can be neglected, considering pusher and valve agglutinate [see
equations (19)]. Therefore impact of pusher about valve as a result has been accepted not
elastic (coefficient of restoration k = 0). After impact recalculation of pusher and valve
speeds from formulas (20) is made at k = 0, i.e. speeds of both bodies are accepted equal
to speed of their center of masses, and the further movement is considered as joint.

Directional control valve. Directional control valve represents a complex of local

resistances formed by its channels and connecting nodes adjoining them r and s. Flow
through each such local resistance is expressed by equation similar to the equation (11):

(21)

where area of through passage section of directional control valve channel

connecting nodes r and s in function of moving of spool z , which maximal value it is

equal to (here conditional pass diameter).

In intermediate position of spool channels can be crossed in one node in which, hence,
there will be a summation or division of flows of working liquid. Therefore flows in
nodes belonging simultaneously various channels of directional control valve, turn out
summation of flows through corresponding channels converging in given node. Hence,
 (22)

where i , , m numbers of directional control valve nodes; flows in

nodes i , , m of directional control valve; are defined by equations of

kind (21).

Change of through passage sections of channels of directional control valve can be

approximated, for example, by trapezoidal characteristic, unequivocally defined by four

positions of spool: (Fig. 4):

Fig. 4. Dependence of through passage section area of channel on spool displacement.

(23)
Diesel engine with a centrifugal regulator. Dynamics of diesel engine with a centrifugal
regulator is described by equation of torque moments on the engine shaft (node j) and
equation of regulator muff movement (node k) [1]:

(24)

where reduced to diesel engine shaft moment of inertia of

rotating details (here moment of inertia of diesel engine; moment of inertia of

pump; transfer number of diesel engine gear); diesel engine

characteristic approximated by finite set of points

increment of torque moment at maximal fuel feed; constant parameters of

diesel engine regulator adjustment; loading moment of pump reduced to diesel

engine shaft; coefficient of viscous friction in diesel engine regulator; transfer

ratio of regulator drive; , F rigidity and force of preliminary compression of spring;
maximal stroke of regulator muff.

Wheel (wheel carrier). For carrying out of tractive-dynamic calculations of hydraulic

volumetric transmissions of self-propelled wheel machines it is necessary to consider
wheel (wheel ) as one of base elements Fig. 1. Indexes i , j , k designate on
the scheme accordingly nodes of input (power shaft of wheel), output (point of contact of
wheel with road) and moving of machine. The considered here model of wheel carrier
describes rigid communication of wheel with the hydraulic motor, i.e. possible elastic
deformations of gear and shaft between hydraulic motor and wheel are not considered.
 Fig. 5. To conclusion of equations of dynamics of wheel.

simplified diagram, b slipping curve, deformation of tire.

In view of the accepted assumptions mathematical model of dynamics of a wheel (wheel

carrier), Fig. 5, looks like:
 (25)

where i wheel moment in view of losses in gear; n moment reduced to shaft of

hydraulic motor; wheel traction reaction (circular force); r dynamic radius of

wheel; efficiency and transfer number of wheel gear; angular speeds

of hydraulic motor shaft and wheel; tangential rigidity of tire; slipping

function (Fig. 5b); mass, speed, displacement and total force of

resistance to machine moving; N number of driven wheels (axes).

In established mode wheel circular force R is connected with relative slipping by the
dependence [1, 6]:

(26)

where

(27)

Here wheel angular speed; v speed of machine progressive movement (node k, Fig.
1).

Value of dynamic radius of wheel r depends on static deflection of wheel under loading

and dynamic change of wheel deflection y (t), depending on mass falling an axis,
rigidity and damping of tires, roughnesses of road structure. In our case it is possible to
consider y (t) as external influence. Then
 (28)

where free radius of wheel; component of machine weight,

falling axis; radial rigidity of tire.

In unsteady mode the dependence (26), having static character, should be replaced by
dynamic model. For this purpose well take advantage offered in [5] technique, according
to which wheel circular force R is function of longitudinal deformation of tire (Fig.
5c), and also compression of fibers running against. After of some transformations [2]
well finally receive the dynamic model of wheel district force R:

(29)

In established mode and then

(30)

i.e. in established mode slipping function is equal to relative slipping of wheel

[compare equations (29) (30) to equations (26) (27)]. Thus, the mathematical model
of wheel (wheel carrier) consists of equations (25) and (30).

Elements of control systems (typical linear dynamic parts of automatic control). In

control systems of volumetric hydraulic drive various physical devices are used:
hydraulic, electromagnetic, electro hydraulic, etc. Therefore at solution of dynamics
problems of hydraulic systems it is necessary to simulate various by nature systems of
control and regulation. The majority of them is well described by means of typical linear
dynamic parts of automatic control [7], to which the following links are related:

1) an ideal intensifying (no inertial) link an adder;

2) the 1-st order aperiodic (inertial) link;

3) the 2-nd order aperiodic link;

4) an oscillatory link;

4a) a conservative link (a special case of an oscillatory link);

5) an ideal integrating link;

 6) an inertial integrating link;

7) an ideal differentiating link;

8) an ideal link with introduction of derivative;

9) an inertial differentiating link;

10) the 2-nd order dynamic link (the general case).

Mathematical models of the listed linear dynamic links are written in the form of ordinary
differential equations, instead of in operational form (in the form of transfer functions) as
transient processes are interested for us in time area, instead of in frequency area.

Generally the 2-nd order linear dynamic link is described by the equation:

(31)

where signals on input of the link; their time derivatives; signal on

output of the link; coefficients of the equation.

For all other types of dynamic links their equations are received as special cases (31):

an ideal intensifying (no inertial) link an adder:

(31.1)

the 1-st order aperiodic (inertial) link:

(31.2)

the 2-nd order (aperiodic or oscillatory) link:

(31.3)

a conservative link:

(31.4)

an ideal integrating link:

 (31.5)

an inertial integrating link:

(31.6)

an ideal differentiating link:

(31.7)

an ideal link with introduction of derivative:

(31.8)

an inertial differentiating link:

(31.9)

Thus, all typical linear links can be incorporated in one generalized element LINK (the
identifier of this element in library of base elements) with nodes i (input), j (output), k
(an additional input for the link adder). Considering specificity of hydraulic systems, in
the right parts of equations of dynamic links as entrance signals pressures can be added:

(32)

Conditions, restrictions, comments. It is necessary to add the resulted equations of

linear dynamic links by some restrictions reflecting physical properties of variables, and
also some design features of devices (for example, detents of mobile parts).

As in the equations superfluous pressure is considered, performance of the conditions is

necessary:

(33)

(34)
where atmospheric pressure; flows in input and output of considered

cavity; coefficient of elasticity of cavity with liquid.

In some real elements movement z of mobile parts is limited by detents. Such

nonlinearity can be written in the form of inequalities:

(35)

(36)

(37)

where L maximal value of movement z ; right part of the differential equation

resolved respect to ; right part of the differential equation resolved respect to .

Let's notice, that the equations for definition of pressure are included into the description
of those elements which contain significant in comparison with other elements volumes
of working liquid (for example, hydraulic cylinders, pipelines, including deadlock,
hydraulic accumulators). Therefore these elements in simplified diagram should be
divided by other hydraulic devices in which compressibility of liquid can be neglected
and which equations serve for definition of flows (for example, hydraulic cylinder cavity
and pipeline, hydraulic accumulator and pipeline, or two consistently connected
pipelines, should be divided by throttle or local resistance that does not contradict
physical sense). It allows to receive the closed system of equations for definition of
pressure and flows in junctions of hydraulic elements.

Forming and solving algorithms of hydraulic circuit math model

Forming of input data. All input information for carrying out of dynamic analysis of
circuit of hydraulic drive consists of two parts:

- information on structure of the considered hydraulic circuit;

- information about physical and design data of the hydraulic circuit elements.
The first part of the input information is formed according to the method of the structure
description of hydraulic circuits stated above, based on classification of base hydraulic
elements, introduction of the generalized three-node element with nodes i (input), j
(output) and k (control, transformation of energy, supply or taking away of power). On a
basis of the entered classification each hydraulic element has received the certain
identifier , designating type of element and unequivocally defining group of equations
for mathematical description of the given type element. According to it special forms
(tables) of input data have been developed.

Each element (except for directional control valves) is described by the line of table of
input data having the following structure:

(38)

where n number of element; matrix-line of coefficients describing physical,

geometrical and design data of the element that makes the maintenance of the second part
of the input information.

At elements having only two nodes (for example, throttle, pipeline, diesel engine) the
third node is designated by zero. Number of element n is intended to choice the necessary
array of factors from general field of input data at forming of system of equations.

As already it was marked above, the unique element which is dropping out of the concept
of a three-node element is a directional control valve as a number of nodes adjoining it
can be more than three. Therefore its description differs from other hydraulic elements.

After numbering nodes of directional control valve it is necessary to write down in pairs
numbers of nodes of its channels in various positions of spool, and the order of following
of nodes (input-output) for each channel of spool is defined by direction of flow of
working liquid. Thus change of direction of flow at change of position of spool can occur
not in whole circuit. For example, in pressure head and drain lines of the directional
control valve the direction of flow does not vary. Therefore for account of the direction of
flow in node for each connection alongside with number of node it is necessary to specify
a sign on flow in this node which is defined by the accepted positive direction of flow in
a pipeline adjoining the given node. Each connection of nodes of directional control valve
represents local resistance with variable area of through passage section depending on
position of spool (Fig. 4).

In view of these features the tables for directional control valves with other structure have
been developed:

(39)
where the identifier of directional control valve; n number of the directional control

valve; numbers of nodes of input ( i ) and output ( j ) of

connections 1..., N ; A matrix-line of coefficients describing physical and design data
of the directional control valve; F a matrix of areas of through passage sections of
connections 1..., N as function of the directional control valve spool movement z, and
besides z is function of time, or function of some parameter (for example, pressure or
movement of hydraulic cylinder piston, etc.).

Representation of input data in such kind allows to make the uniform description of the
circuit as switching of a spool from one position in another will automatically define the
scheme of connections of elements.

For forming of mathematical model of hydraulic system dynamics it is necessary to give

also parameters of a working liquid entering into the equations (density, kinematic
viscosity, volumetric module of elasticity).

Forming of mathematical model of hydraulic system as a whole. As a result of

analysis of line of the table of input data for each element depending on its identifier the
system of differential and-or algebraic equations of a kind is formed:

(40)

where generalized variables in nodes ; dimension of system of equations of the

given type element; s dimension of system of differential equations;

accept values , i.e. numbers of the nodes corresponding the given element; the

concrete kind of right parts , physical sense of variables , dimensions m

and s are unequivocally defined by the identifier of element.

For directional control valves the analysis of connections of its nodes is preceded with
forming of the equations, as in intermediate position of a spool (at its switching from one
position in another) in one node some connections can be crossed. Therefore flows in
nodes belonging simultaneously various connections, turn out summation of flows in
corresponding connections [see the equations (22), being analogue of the Kirchhoffs first
law for electric circuits].
The description of each hydraulic element is realized generally by two separate blocks: D
(differential equations of mathematical model of element) and-or A (algebraic or
transcendental equations of mathematical model of element).

On a basis of input information the following fields of input data are formed.

Matrix of communications:

(41)

differing matrix S [see (1)] presence of an additional column of numbers of

elements.

Matrix of parameters of elements of hydraulic system:

(42)

where arrays of parameters of pumps; arrays of parameters of hydraulic

motors; arrays of parameters of hydraulic cylinders etc.; arrays of

parameters of directional control valves; number of types of elements in considered
classification (can replenish); n =1, 2, numbers of the given type elements.

Forming of mathematical model of hydraulic system is carried out on the following

algorithm. The element (m = 1..., N) is considered, its comparison with each of

possible identifiers (PUMP, MOTOR, PIPE, ...) is made. At concurrence to one of them
the reference to the block of differential (D) and-or algebraic (A) equations is made with

transfer of specification: . By means from matrix its element

(a line of factors) is selected, where I corresponds to the hydraulic element

identifier defined before it. As a result the required equations in which the necessary
coefficients are substituted, get out of the general library of mathematical models. Then
there is a transition to a following element , etc. until the list of the hydraulic circuit
elements (column of matrix ) will be completely settled, that means the end of
forming process of system of equations.

External influences and control signals. Control of model (the system of the equations
solving) is carried out by the special block which function includes generating signals of
external influence: forces of resistance, external loadings in separate elements of
hydraulic system (hydraulic motors, hydraulic cylinders), switching of operating
hydraulic elements (spools of directional control valves, operated valves, adjustable
throttles, pumps, etc.); stop of solving on the given condition, etc. In the control block it
is possible to simulate as typical external influences (sine wave, intermittent, linear, etc.),
and non-standard, taking place in most cases and defined by a specific problem.
Moreover, for consideration of problems with changing physical and design data
(variable masses and moments of inertia, pressures of adjustment of valves, etc.) in the
control block it is possible to provide the task of these values as function of time or other
variable received as a result of solution. Besides in the control block the forming of
operating influences and forces of resistance as the functions approximated by a final set
of discrete values or having a certain spectrum is obviously possible.

Algorithm of solving. For integration of systems of the differential equations now there
is a huge set of methods of numerical integration (Runge-Kutta, Eulers, Gear's methods
and their updating, etc.), on a basis of which a majority of various corresponding
programs has been developed that allows to choose the suitable tool of the solution
always. However, in our case of simulation of dynamics of hydraulic systems there is a
feature, consisting that the received system of the equations the mixed type, alongside
with differential it contains also algebraic (transcendental) equations for definition of
flows of pumps, hydraulic motors, losses of pressure on length of pipelines, polytropic
process in a gas cavity of the hydro pneumatic accumulator, various nonlinearity. The
solution of such systems of the equations in the closed form (analytically) is not
obviously possible because of insuperable complexities of transformations necessary for
it. Therefore for search of the numerical solution it is possible to act as follows. Having

values of pressure on input of the pipeline on n-th step of integration , pressure upon

output well define, using the approached equation:

(43)

i.e. having taken values on previous (n 1)-th step of integration.

In view of small step of numerical integration, and also small all second addendum
composed in the right part (43) an error received at such replacement, is negligible small.
By virtue of the stated reasons the equation of losses of pressure on length of the
pipelines, written down in the form of (43), yields quite satisfactory results and allows to
solve other equations (for definition of flows) in a finite kind.

Form of representation of results of calculation

Results of the dynamic analysis of hydraulic drive circuit can be presented either in a
tabular-numerical kind (listing), or in the form of graphs of dependences interesting us.

The tabular-numerical form of results of calculation (output listing) is constructed as

follows. As in each node of hydraulic system the following combinations of physical
variables are possible: pressure flow of liquid, force linear speed linear
displacement, torque moment angular speed turn angle, it is possible to pass
pressure to the integrated system of physical variables: "forces" (forces, pressures,
torque moments), "speeds" (linear or angular ones, flow of liquid), "displacements"
(linear or angular ones) which are indexed by numbers of nodes of the circuit. Then
according to it the structure of results of the calculation presented in target listing, is
those:

Time, s

Number of node "force" "speed" "displacement"

Number of node "force" "speed" "displacement"
. . . . . . . . . . . . .
Number of node "force" "speed" "displacement"

________________________________________________________________________

Time, s

Number of node "force" "speed" "displacement"

Number of node "force" "speed" "displacement"
. . . . . . . . . . . . .
Number of node "force" "speed" "displacement"

_______________________________________________________________

Time, s

Number of node "force" "speed" "displacement"

Number of node "force" "speed" "displacement"
. . . . . . . . . . . . .
Number of node "force" "speed" "displacement"

_______________________________________________________________
That is, with the certain step on time for each number of node the three of numbers
stands out: "force", "speed", " displacement ", defining for the given time moment
values of physical variables operating in the given node. These records stand out until the
time interval given for calculation is settled, or there is no emergency stop of the
program. In both cases last data describing a condition of hydraulic system (control
point), are remembered by the program and since this moment it is possible to continue
calculation, having give the longer time interval. Certainly, the emergency stop of the
program will demand check of the created situation and its correction for the further
continuation of calculation.

Examples

Below a number of examples for an illustration of opportunities of the developed

algorithm of simulation of dynamics of hydraulic systems is resulted. In all examples the
analysis of transient processes in the chosen circuits of hydraulic drive which can be
corrected by a choice of separate parameters of hydraulic elements or change of the initial
circuit is spent.

1. Hydraulic systems pump - hydraulic actuator

Let's consider most often meeting hydraulic circuit including the pump with fixed
displacement, a hydraulic actuator (cylinder or motor), necessary connecting pipelines
and a pressure relief valve. At all traditional character of the presented hydraulic circuit a
number of variants of every possible combinations of parameters is so great, that in
practice it is necessary to spend dynamic analysis for each concrete case. On Fig. 6 some
characteristic examples of such hydraulic circuits are presented.
Fig. 6. Examples of characteristic hydraulic circuits and their transient processes.
Specially not citing input constructive data of separate hydraulic elements, well stop on
the structure description of the hydraulic circuit according to the form offered above (41)
and character of transient processes.

The circuit shown on Fig. 6, consists of 9 elements connected in 14 nodes. Its structure
described by means of a matrix of communications (41), looks like:

PUMP 1 5 6 2
PIPE 1 6 4 0
PIPE 2 8 9 0
PIPE 3 3 7 0
TEE 1 4 3 8
THROTTLE 1 7 12 0
THROTTLE 2 13 14 0
CYLINDER 1 12 13 1
VALVE 1 9 10 11

For the hydraulic system the following initial conditions are accepted: speed and
movement of the hydraulic cylinder piston are equal to zero, angular speed of the pump
shaft is constant, all flow from the pump goes into a pipeline 6 4. Mathematical model
of drive is system of differential-algebraic equations of the 24-th order. The solution of
the system of equations is a set of values of pressures, flows of a liquid, speeds and
movements in all nodes of hydraulic system as function of time. On Fig. 6 it is shown,
that in initial time moment a peak of pressure 12 takes place in a piston cavity of the
hydraulic cylinder which exceeds pressure of adjustment of a pressure relief valve then
insignificant fluctuations of pressure concerning a level of adjustment of a pressure relief
valve begin. Thus there is a racing of the hydraulic cylinder piston (speed of the piston v1
increases). Fluctuation of pressure 12 is consequence of operation of the valve and
fluctuation of its shutter z11.

In process of the piston racing, since the time moment A, pressure 12 in a piston cavity of
the cylinder starts to fall, but the piston still moves by inertia. Thus the valve already is
completely closed. Fluctuations of pressure 12 and speeds v1 depends on a combination of
parameters of the system. The transient process duration is nearby 0.3 s.

On Fig. 6b the similar circuit is shown, but instead of the hydraulic cylinder the hydraulic
motor is used. There are 7 elements and 12 nodes in the circuit, it is described by system
mixed differential- algebraic equations of the 20-th order. Initial conditions: angular
speed and a turn angle of the hydraulic motor shaft of are equal to zero; angular speed of
the pump shaft is constant. At the initial time moment a sharp peak of pressure 11 takes
place which exceeds pressure of adjustment of a pressure relief valve; thus the valve
works (z1) and the hydraulic motor shaft, which moment of inertia is insignificant, is
raised. Due to initial peak of pressure angular speed of the hydraulic motor shaft is above
its established value. As a result pressure falls, that leads to reduction of the hydraulic
motor angular shaft speed. Further in system insignificant fluctuations of angular speed
and pressure are observed. Duration of the considered transient process is nearby 0.1 s.

On Fig. 6c the circuit of a hydraulic drive with the pump working on two in parallel
connected hydraulic cylinders is presented. The number of elements is equal 7, number of
nodes 12. The mathematical model of hydraulic system consists from 20 algebraic and
differential equations. On oscillograms Fig. 6c transient processes are shown at identical
(I) both various (II) loadings and sizes of hydraulic cylinders. Initial conditions: speeds
and movements of pistons are equal to zero; angular speed of the pump shaft is constant.
In the symmetric circuit (oscillogram I) in the initial time moment there is a sharp jump
of pressure 6,10 . In process of increase in pressure raising of pistons of hydraulic
cylinders (speed v8,12) begins, then there is a falling pressure 6,10 up to zero to reduction of
speeds of movement and the following output by the established values. Practically
transient process in this case is close to shown on Fig. 6, but differs pressure of
adjustment of pressure relief valve. However at different loadings and sizes of hydraulic
cylinders character of transient processes changes (see oscillogram II). The hydraulic
cylinder piston with smaller loading more quickly moves. And besides, upon termination
of transient process the hydraulic cylinder piston with greater loading stops, while the
hydraulic cylinder piston with smaller loading continues to move with the speed
corresponding the pump flow. For this case force acting on the cylinder rod in node 12, is
less than the force enclosed to a rod of other cylinder in node 8. Therefore speed v12 is
more than speed v8 , and v12 tends to the established value defined by the pump flow
whereas v8 tends to zero. Pressures in piston cavities of cylinders to within losses of
pressure in a tee are identical. Duration of transient process is approximately 0.1 s.

On Fig. 6d the circuit of a hydraulic drive in which the pump works on two in parallel
connected hydraulic motors is shown. The circuit consists of 7 elements and 12 units and
is described by system of the algebraic-differential equations of the 20-th order. As
loadings on hydraulic motors shafts are identical, transient process is similar to the circuit
with symmetric loadings on hydraulic cylinders. Time of transient process is 0.1 s.

At last, on Fig. 6e the circuit in which the pump works on two consistently connected
hydraulic cylinders is shown. There are 8 elements and 13 nodes in the circuit. It is
described by system of the differential-algebraic equations of the 21-st order. The
transient process is fixed on the oscillogram, corresponds to zero initial values of speeds
v10 , v13 and movements z10 , z13 of hydraulic cylinders pistons at constant angular speed of
the pump shaft. Feature of the circuit is that rod cavity of hydraulic cylinder I is
connected to a piston cavity of the hydraulic cylinder II, therefore pressure 3 is more
than pressure 11. Redistribution of flows Q3 and Q11, and also speeds v10 and v13 is
defined by a combination of parameters of system as a whole.

2. System diesel engine - pump - loading

In the examples considered above an angular speed of the pump shaft was accepted by a
constant. In real hydraulic systems where as the primary engine the internal combustion
engine is often used, with increase of loading (pressure in hydraulic system) angular
speed of a shaft of the engine (hence, and the pump) decreases. If in the examples
considered above to consider also this factor a character of transient processes can
become complicated considerably.

Fig. 7. An example of simulation of dynamics of hydraulic system with diesel engine

a simplified circuit, b change of the engine shaft moment in function of time

and angular speed of a shaft, c the same at various values of coefficient of
viscous friction of centrifugal regulator

Let's consider a following example (Fig. 7). The diesel engine with a centrifugal regulator
drives the fixed displacement pump on which output the throttle simulating loading in
hydraulic system is established. The structure of the circuit (fig. 7) is described by the
following matrix of communications:

DIESEL 1 0 2 1
PUMP 1 5 6 0
PIPE 1 6 4 0
THROTTLE 1 4 3 0

The number of the circuit elements is equal 4, number of nodes 6. The order of the
solved mixed system of the differential-algebraic equations 9.

On Fig. 7b the external static characteristic of a diesel engine with the imposed on it
phase diagram of change of the moment versus angular speed of the engine shaft for two
values of pressure 6 of adjustment of a throttle is resulted: 4.8 MPa and 9.2 MPa.

From Fig. 7b it is visible, that a range of angular speed change according to the static
characteristic st for M = 153 Nm makes st1 = 5 is rad/s, and for M = 258 Nm st2
= 8 is rad/s. Corresponding ranges of angular speed change on a dynamic characteristic
dyn make: dyn1 = 10 rad/s and dyn2 = 17 rad/s. Thus there are also significant
changes of the diesel engine loading moment.

The specified dynamic characteristics of diesel engine essentially depend on parameters

of centrifugal regulator. So on Fig. 7c it is shown, that at change of coefficient of viscous
friction from 4400 Ns/m (curve 1) up to 7350 Ns/m (curve 2) dyn decreases for 30
%. The resulted example shows, that the assumption about constancy of angular speed of
the pump shaft in real conditions can appear rather disputable.

3. Dynamics of pilot operated check valve at lowering hydraulic cylinder piston

 Fig. 8. Dynamics of pilot operated check valve at lowering hydraulic cylinder piston

a simplified circuit, b transient processes

Let's consider as an example the circuit of a hydraulic drive (Fig. 8), including the
hydraulic cylinder (nodes 13-11-12), pipelines (9-14, 10-3, 5-4, 2-1), tee (3-4-2), local
resistance (14-13 and 11-10) and pilot operated check valve consisting of the check valve
(6-9-8) and pusher (6-5-7). Continuous arrows on the circuit note a positive direction of
flows in a mode of the hydraulic cylinder piston rise. In this case pilot operated check
valve works as usual check valve. By dotted arrows the negative direction of flows (a
mode of lowering of the piston) is shown, thus pressure from basic pipeline 1-2 moves
simultaneously in a rod cavity of hydraulic cylinder and under the piston of pusher (node
5), which raises the valve, providing the pass of liquid from the hydraulic cylinder and by
that lowering of the hydraulic cylinder piston. Into the hydraulic system (node 1) the
negative flow Q = 200 l/min (according to the accepted direction of flows) moves. The
hydraulic circuit contains 9 elements and 14 nodes and is described by system of
differential-algebraic equations of the 31-st order. Main parameters of the hydraulic
system:

hydraulic cylinder:

piston diameter 100 mm,

rod diameter 50 mm,

piston stroke 1000 mm,

mass reduced to rod 8000 kg,

weight of working equipment reduced to rod ~ 80 000 N;

pipelines:

internal diameter 20 mm,

lengths of pipelines: (2-1) 2m, (10-3) 2m, (5-4) 1m, (9-14) 1m;

pilot operated check valve:

pusher mass 0.3 kg,

valve mass 0.1 kg,

pusher operating area 15.9 cm,

valve operating area 5.3 cm,

pusher stroke 11 mm,

initial clearance between pusher and valve 6 mm,

coefficient of viscous friction of valve 300 Ns/m,

valve spring rigidity 5200 N/m,

valve saddle diameter 26 mm,

valve cone angle 70,

flow coefficient 0.62;

throttle (13-14):

conditional pass diameter 7 mm,

flow coefficient 0.62;

working liquid:
density 900 kg/m,

kinematic viscosity 310-5 m/s,

volumetric module of elasticity 5108 N/m.

On Fig. 8b transient processes in considered hydraulic system in a mode of lowering the

hydraulic cylinder piston are presented. In initial time moment the system is in balance,
and the effort to a rod 80 000 N is counterbalanced by static pressure in a piston cavity
10.4 MPa. At submission into the hydraulic system of flow of a liquid of 200 l/min
pressures in a rod cavity of the hydraulic cylinder and simultaneously under the pusher
piston 5 begin to increase. At t 0.006 s when 5 reaches value 3.5 MPa, thus 5
0.339, the valve of the pilot operated check valve (z8 changes from 0 up to 5 mm) opens,
pressure of a liquid in a cavity before valve 9 falls, and pressure in a rod cavity by virtue
of inertia of the reduced mass of the hydraulic cylinder continues to grow (speed v12 in
this period of time is small). Pressure 5 jump up to 12.6 MPa and pressure 13 drop up to
3.5 MPa are as result observed. In process of the hydraulic cylinder piston raising
pressure 5 decreases, and 13 increases, there are fading fluctuations of pressure 5 and
13 and the hydraulic cylinder piston speed v12 with frequency about 6 Hz in the system.
High-frequency fluctuations of the valve of the pilot operated check valve with frequency
of 250...500 Hz and amplitude of 0.5...2 mm caused rebounds of the valve from a pusher,
reached emphasis, and their subsequent impacts at the same time take place. However
some appreciable influence on target parameters of hydraulic system (pressure 13 in a
piston cavity of the hydraulic cylinder, the pistonmoving speed v12) dynamics of the pilot
operated check valve does not render. Nevertheless it is necessary to emphasize, that for
achievement of a steady operating mode of the pilot operated check valve and hydraulic
system as a whole it is necessary to choose correctly through passage section area of
element 13-14. Otherwise, as has shown the analysis of the same circuit, the system
becomes unstable. For example, at diameter of a throttle 13-14 equal of 20 mm, there is
the significant dynamics, accompanied hydraulic impacts in the system. Therefore for
realization of a smooth mode of lowering of the piston in a wide range of loadings in
hydraulic systems alongside with the pilot operated check valve usually establish the
brake valve providing regulation of speed of lowering of working bodies in function of
loading.

4. Hydraulic drive of lowering of hydraulic excavator arrow

At lowering an arrow of hydraulic excavator with sharp braking (pickup) there are the
high peak pressure, being consequence of hydraulic impact in hydraulic system. For a
correct choice of a pressure relief valve carrying out of dynamic analysis of hydraulic
system is necessary [9]. Well consider the circuit of a hydraulic drive of lowering of an
arrow of excavator, resulted on Fig. 9. The circuit contains 15 elements and 21 nodes
and is described by system of nonlinear algebraic- differential equations of the 38-th
order.
 Fig. 9. Dynamics of hydraulic system of excavator at sharp braking of arrow

a simplified circuit, b results of analysis, c experimental data

Lowering of hydraulic excavator arrow is made by two identical hydraulic cylinders

which drain pipelines are united in node 4 in the general drain line. Braking of an arrow
is carried out by overlapping of a spool (throttle 11-12). Flows of a working liquid from
pump are shown on the circuit as time-dependent flows Q2 and Q16.

At raising of hydraulic cylinders pistons in the beginning of lowering values Q2 and Q16
accrue from zero up to the established value corresponding the pump flow, and at braking

flow of a liquid in hydraulic cylinders stops. Thus, the area of through passage
sections of throttle (11-12) and flows of working liquid Q2 and Q16 are defined by
dependence:
Here: f is , either Q2, or Q16, and f max accordingly, the maximal area ( )max of
through passage section of throttle (11-12) or Qp / 2, where Qp = 350 l/min the pump
flow; time of regulation (it is accepted = 0.1 s); l position of the hydraulic cylinder
piston at the beginning of braking (it is accepted l = 700 mm); z1 current position of the
hydraulic cylinder piston; t 0 the time moment of braking beginning.

Basic parameters of the hydraulic system:

hydraulic cylinders:

piston diameter 125 mm,

rod diameter 80 mm,

piston stroke 1000 mm,

mass reduced to rod 17 660 kg,

weight of working equipment reduced to rod ~ 76 500 N,

pipelines:

internal diameter 25 mm,

lengths of pipelines: (4-5) - 0.8 m, (6-11) - 0.2 m, (7-8) - 0.2 m, (12-13) - 2.5 m, (18-20) -
2.8 m, (19-21) - 2.8 m,

pressure relief valve (4 variants):

variant 1 2 3 4

mass of moving part, kg 0.142 0.108 0.142 0.074

spring rigidity, N/m 9.8104 10.6104 9.8104 9.8104

working area from a pressure, cm 1.77 1.33 1.77 1.77

working area from a drain, cm 8.05 6.15 8.05 8.05

average diameter of throttle crack, mm 15 13 15 15

valve cone angle 60,

flow coefficient 0.62;

tees:

diameters in nodes of tees: 25 mm, 25 mm, 25 mm;

coefficients of local resistance of branches of tees: (5-6-7) - 0.2, 1.0, 1.0; (20-21-4) - 2.5,
2.5, 2.5;

throttles:

area of through passage section of throttles: (3-18) - 4.9 cm, (11-12) - 4.9 cm
(maximal), (13-14) - 2.44 cm, (17-19) - 4.9 cm,

flow coefficient 0.62;

working liquid:

density 900 kg/m,

kinematic viscosity 210-5 m/s,

volumetric module of elasticity (2 variants) 4.9108 N/m and 9.8108 N/m.

On Fig. 9b,cestimates and experimental dependences of transient processes in hydraulic

system of a excavator are presented for comparison at lowering an arrow with pickup
(sharp braking) at pressure of adjustment of pressure relief valve 30 MPa. Estimate value
of peak pressure in a piston cavity of the hydraulic cylinder of rise-lowering of an arrow
has made 28.6 MPa and differs from value 26 MPa, received in experiment, on 10 %. As
a whole, apparently from oscillograms, character of estimate dependences of pressure
and movement of hydraulic cylinder rod (Fig. 9b), is close to received by experimental
way (Fig. 9c). Duration of transient processes is 0.1...0.15 s.

5. Main hydraulic drive of automobile concrete pump

 Fig. 10. Simplified circuit of main hydraulic drive of automobile concrete pump

On Fig. 10 the simplified circuit of main hydraulic drive of automobile concrete pump is
presented. As one cycle of work of hydraulic cylinders of main hydraulic drive is
considered only, such elements as valves and directional control valves switching of
hydraulic cylinders from suction tact to injection tact of a concrete mix are not included
in the simplified circuit. Thus, the simplified circuit of main hydraulic drive of
automobile concrete pump consists of 12 elements connected in 21 nodes, and is
described by the mixed system of differential and transcendental equations of the 36-th
order.

Basic parameters of the hydraulic system:

pump: 207.32

power regulator: 400.32

power ~51.5 kW,

pressure of operation ~13 MPa,

hydraulic cylinders:

piston diameter 100 mm,

rod diameter 63 mm,

piston stroke 1400 mm,

pressure relief valve: 510.32 (non direct action)

pressure of adjustment ~20.6 MPa,

pipelines:

steel pipe (2-14): diameter 40 mm, length 1.2 m,

sleeve of high pressure (15-4): diameter 32 mm, length 1.65 m,

steel pipe (16-17): diameter 20 mm, length 1.0 m,

throttles:

(4-5): area of through passage section 12.56 cm, flow coefficient 0.62,

(10-11): area of through passage section 12.56 cm, flow coefficient 0.62,

(6-8): area of through passage section 8.04 cm, flow coefficient 0.62,

tee (14-15-16):

diameters in nodes of tee: 40 mm, 32 mm, 20 mm,

coefficients of local resistance of branches of tees: 2.5, 2.5, 2.5;

working liquid:

density 900 kg/m,

kinematic viscosity 310-5 m/s,

volumetric module of elasticity 9.8108 N/m.

Fig. 10b. Dynamics of main hydraulic drive of automobile concrete pump
Loading from a column of the concrete mix, acting on the concrete mix cylinders pistons,
rigidly connected by the general rods with pistons of hydraulic cylinders, was given by
two components: variable force as function of the hydraulic cylinder piston movement z7,
simulating process of compression of mix in view of incomplete filling of concrete mix
cylinders, and process of its moving with the certain resistance (this dependence graph
R(z7) is presented on Fig. 10b), and variable mass m(z7), reduced to the hydraulic cylinder
rod (Fig. 10b), equal to sum of masses of the hydraulic cylinder piston and rod and the
concrete mix cylinder piston on an initial piece of moving (z7 0.35 m, Fig. 10b) and
undergoing jump at z7 = 0.35 m in view of addition of mass of column of concrete mix.
Clearly, that such model of loading does not consider possible fluctuations of pressure in
a concrete mix. However, the account of this component is a subject of special researches
and becomes possible only after carrying out of corresponding experiments with the
purpose of studying of character of wave and oscillatory processes in concrete pipe.

For simulation of emergency operation of sharp braking of the hydraulic cylinder rod in
view of sharp increase of loading (with the purpose of studying of dynamics of hydraulic
system at operation of a pressure relief valve) the case of jump of loading has been in
addition considered at z7 > 0.7 m (see graph R(z7) on Fig. 10b) up to a level maximal
loading. As a result of dynamic calculation transient processes of pressure 5 in a piston
cavity of the hydraulic cylinder (5-6-7), speed v7 and movement z7 of this hydraulic
cylinder rod and to other phase variables of the hydraulic system in function of time t
have been received. Smooth enough change of pressure 5 is characteristic, despite of
jump of the reduced mass which has affected only own frequency of the fluctuations,
changed with 30 Hz up to 11.4 Hz. The mode of the maximal loadings has been
considered both at the disconnected power regulator, and at its connection in the circuit.
At sharp increase of loading R with 68.6 kN up to 343 kN and consequently, and pressure
5, alongside with a pressure relief valve also power regulator are worked, reducing the
pump working geometric volume on ~39 % of its maximal value. However, as the
analysis has shown, it has not rendered essential influence on dynamics of drive.
Presence of power regulator has affected only decrease in average value of pressure 5
approximately on 0.7 MPa.