Search Results (13)

This study introduces a comprehensive modeling framework for the evaluation of automotive hydraulic shock absorbers, developed on the basis of an interdisciplinary coupled model that integrates the shock absorber and the servo-hydraulic test-rig subsystems. The coupled formulation captures the key dynamic interactions within the damper assembly and establishes a virtual experimental environment for multi-criteria design exploration and optimization. Three interdependent performance objectives are addressed concurrently: (i) ensuring damping-force conformity within specified tolerance limits to maintain vehicle stability and safety, (ii) minimizing vibration amplitudes, quantified by piston-rod acceleration as an NVH (Noise, Vibration, and Harshness) performance indicator, and (iii) evaluating the fatigue life of the shim-stack valve system based on alternating stress analysis and experimentally determined Wöhler material characteristics, to ensure long-term operational durability. A Pareto-frontier-based multi-objective optimization strategy is applied to identify and interpret the trade-offs and synergies among these competing criteria. The resulting set of non-dominated solutions provides engineering insight into optimal configuration selection under conflicting design constraints, thereby supporting early-stage, risk-informed decision-making in the development of advanced suspension systems. Full article

Free stroke, which means the intermittent no-load operation state of dampers, can cause an abnormal noise and unavoidably lead to the deterioration of vehicle NVH performance. In electric vehicles, the noise is particularly intolerable because there are no engine sounds to mask it. Focusing on this, the mechanism of the free-stroke phenomenon is analyzed. A method, which involves parametric models and numerical simulation, is proposed to prevent free-stroke phenomena during the damper design phase. This paper proposes a free-stroke mechanism based on a fluid–structure interaction (FSI) numerical method, combined with experiments, which intends to provide a design reference with guaranteed performance for dampers. Initially, according to parametric cavitation models and by applying numerical methods, simulations for the proposed FSI model are calculated. By analyzing the simulation results, strain variation characteristics near the bottom of the damper valves are revealed, which establish the relationships between strain change, cavitation and the free-stroke phenomena. Meanwhile, the specific position and distribution of free-stroke failure are clearly located by running diverse loading speeds. Finally, all the theoretical analysis results are verified using damper noise tests and indicator bench tests. Full article

This study introduces a novel magnetorheological (MR) damper for semi-active vehicle suspension systems that enhance ride comfort and handling stability. The proposed damper integrates reverse and normal damping modes, enabling independent control of rebound and compression strokes through an external MR valve. This configuration supports four damping modes—Soft/Soft, Hard/Soft, Soft/Hard, and Hard/Hard—allowing adaptability to varying driving conditions. Magnetic circuit optimization ensures rapid damping force adjustments (≈10 ms), while a semi-active control algorithm incorporating skyhook logic, roll, dive, and squat control strategies was implemented. Experimental validation on a mid-sized sedan demonstrated significant improvements, including a 30–40% reduction in vertical acceleration and pitch/roll rates. These enhancements improve vehicle safety by reducing body motion during critical maneuvers, potentially lowering accident risk and driver fatigue. In addition to performance gains, the simplified MR damper architecture and modular control facilitate easier integration into diverse vehicle platforms, potentially streamlining vehicle design and manufacturing processes and enabling cost-effective adoption in mass-market applications. These findings highlight the potential of MR dampers to support next-generation vehicle architectures with enhanced adaptability and manufacturability. Full article

The elastic valve plate and guide flow disc are key components that influence parameters such as opening and pressure difference of pilot-relief valve, which are also the core components enabling continuous damping adjustment in valve-controlled continuously variable dampers. Based on deformation characteristics of elastic valve plate and various structural types of guide flow disc, this paper reveals the impact of structural types of guide flow disc and design parameters of elastic valve plate on the performance of pilot-relief valve and obtains the relationship curves between opening pressure, pressure difference and opening of relief valve versus structural types and the angle, width and the number of arc plates of elastic valve plate. It shows that the pressure difference of the relief valve reaches maximum with min angle, max width, most arc plates and irregular-shaped type, and the opening reaches maximum with max angle, min width, fewest plates and round hole type. By adjusting structural types of guide flow disc and design parameters of elastic valve plate, the pressure difference and opening of the relief valve can be precisely controlled, providing theoretical support for the precise design of pilot-relief valve and the optimization of damping characteristics. Full article

Ensuring adequate comfort and safety in vehicle motion is a subject of extensive research worldwide. Despite the implementation of new control algorithms, including those leveraging AI, the application of effective semi-active vibration dampers remains crucial for achieving optimal suspension performance. This article presents experimental studies conducted on a vehicle equipped with semi-active suspension featuring custom-designed hydraulic dampers controlled by piezoelectric valves. These innovative dampers are characterized by extremely short response times, enabling real-time adaptation to varying driving conditions. A simple control algorithm designed to operate based on real-time signals from suspension sensors is introduced and evaluated. The experimental setup, including the measurement system used during testing, is described in detail. The presented results highlight the significant potential of this approach for improving driver comfort under specific driving conditions, even without detecting road roughness ahead of the vehicle. Full article

This study investigates the transient flow dynamics and pressure interactions within Tesla valve configurations through comprehensive CFD simulations. Tesla valves offer efficient passive fluid control without the need for external power, making them favorable in various applications. Previous observations indicated that Tesla valves effectively reduce the amplitude of pressure transients, prolonging their duration and distributing energy over an extended timeframe. While suggesting a potential role for Tesla valves as pressure dampers during transient events, the specific mechanisms behind this behavior remain unexplored. This research focuses on elucidating the internal dynamics of Tesla valves during transient events, aiming to unravel the processes responsible for the observed attenuation in pressure transients. This study reveals the emergence of “pressure pockets” within Tesla valves, deviating from conventional uniform pressure fronts. These pockets manifest as discrete chambers with varying lengths and volumes, contributing to the non-uniform propagation of pressure throughout the system. This investigation employs advanced CFD simulations as a crucial tool to unravel the governing dynamics of transient flow within Tesla valve configurations. By elucidating underlying fluid dynamics, this study lays the groundwork for future Tesla valve design optimization, holding potential implications for applications where the control of transient flow events is crucial. Full article

A detailed study of the gas-dynamic behaviour of both liquid and gas flows is urgently required for a variety of technical and process design applications. This article provides an overview of the application and an improvement to thermal anemometry methods and tools. The principle and advantages of a hot-wire anemometer operating according to the constant-temperature method are described. An original electronic circuit for a constant-temperature hot-wire anemometer with a filament protection unit is proposed for measuring the instantaneous velocity values of both stationary and pulsating gas flows in pipelines. The filament protection unit increases the measuring system’s reliability. The designs of the hot-wire anemometer and filament sensor are described. Based on development tests, the correct functioning of the measuring system was confirmed, and the main technical specifications (the time constant and calibration curve) were determined. A measuring system for determining instantaneous gas flow velocity values with a time constant from 0.5 to 3.0 ms and a relative uncertainty of 5.1% is proposed. Based on pilot studies of stationary and pulsating gas flows in different gas-dynamic systems (a straight pipeline, a curved channel, a system with a poppet valve or a damper, and the external influence on the flow), the applications of the hot-wire anemometer and sensor are identified. Full article

This paper has proposed a new hydro-pneumatic damper, allowing independent accumulator pressure compressibility from the chamber pressure which enhances isolation performances due its lower F-V hysteresis effect at moderate velocities. The system utilizes the generic hydraulic damper with two hydro-pneumatic accumulators and four check valves in its design. To evaluate the active suspension capability of proposed damper effectiveness, a 22-degrees-of-freedom (DOF), four-axle truck model is integrated with a hydraulic control valve, which is built in an LMS-AME sim environment. Then, the model is exported as an S-function into Matlab/Simulink co-simulation platform for the hydraulic servo-valve control input of a model predictive control (MPC) and proportional-integral-derivative (PID) output signal. Simulation results show that the MPC and an additional supply of fluid to the proposed damper provide better performances and an adaptive damping capability is established. This work also showcases the development and results of a roll interconnected suspension study to assess the proposed damper characteristics when it is interconnected. The various advantages of the proposed-HPIS system over the well-known hydraulic interconnected system (HIS) and hydro-pneumatic interconnected suspension (HPIS) system are studied. Full article

To satisfy the design requirements for a hydropneumatic spring damper valve, the inlet–outlet pressure drop (ΔP) and the axial force on the spool (F_Z) of a valve were investigated using fluid–solid coupling simulations and multi-objective optimization, along with the effects of the diameters of three internal holes (D_A, D_B, and D_C) in the valve on the ΔP and the F_Z. First, a meshed computational fluid dynamics model of a damper valve was established based on its geometric structure. Next, the effects of the flow rate (Q) and the diameter of the damping hole in the internal structure on the ΔP and the F_Z of the damper valve were investigated. The results showed that the ΔP and the F_Z varied nonlinearly with Q. For a given Q, the ΔP decreased as D_A, D_B, and D_C increased. For a given Q, the F_Z was not related to D_A and D_C, but it decreased as D_B increased. Finally, the structure of the damper valve was optimized by defining the ΔP and the F_Z as the response variables and D_A, D_B, and D_C as the explanatory variables. The results showed that the best configuration of the hole diameters was D_A = 8.8 mm, D_B = 5.55 mm, and D_C = 6 mm. In this configuration, ΔP = 0.704 MPa and F_Z = 110.005 N. The ΔP of the optimized valve was closer to the middle value of the target range than that of the initial valve design. The difference between the simulated and target values of the F_Z decreased from 0.28% to 0.0045%, satisfying application requirements. Full article

The main function of the vent valve is to release part of the air at the outlet of the axial compressor to prevent engine surges. The damping parameters have an important effect on the opening and closing characteristics of the vent valve. The control characteristics of each component were obtained by finite element analysis and testing. The overall model of a two-stage partial pressure vent valve was established, and the reliability of the model was verified by testing. The opening and closing characteristics of the damper valve with different damping parameters were obtained by parametric simulation. The results show that there was a pressure mutation point in the middle support pressure and the pressure in the control chamber during operation of the vent valve, which made the valve open and close quickly. The damping hole of the middle shell and the middle nozzle of the support had the greatest influence on the open-close pressure ratio. The damping hole and nozzle of the middle shell had the greatest influence on the opening and closing stability. The results are used to guide the structural design, and the analytical method provides a theoretical basis for research of the same type of valve. Full article

Specifications of actuators when interacting with biological systems such as the human body are entirely different from those used in industrial machines or robots. One important instance of such applications is assistive devices and prostheses. Among various approaches in designing prostheses, recently, semi-active systems attracted the interest of researchers. Even more, some commercial systems benefit from designs such as implementing an adjustable damper in the ankle prosthesis to increase range of motion. The main reason for adding damper is to assist amputees’ walking locomotion on slopes (especially downward). In this paper, we introduce a hydraulic damper design for use in the transtibial prosthetic foot. In the fabricated hydraulic prosthetic foot, two one-way flow control valves are exploited to tune the damping ratio in the plantar flexion and dorsiflexion, independently. Using the carbon prosthetic foot in series to a damper and spring could improve mimicking intact foot movement. First, we present the details of the damper and the prosthesis mechanical design. Then, we introduce experiment-based modeling for the damper’s conceptual design in the proposed prosthesis using SIM-Hydraulic and MATLAB. This device is fabricated and tested in a pilot experiment. The compact design with reduced weight and size of the prosthetic foot are additional advantages of the proposed prosthetic foot. Full article

This paper characterizes the static, dynamic, and controlled behavior of a high-performance electro-hydraulic actuator to assess its suitability for use in evaluating machine tool behavior. The actuator consists of a double-acting piston and cylinder arrangement controlled by a servo valve and a separate rear chamber controlled by a separate valve, designed to work in conjunction to generate static forces of up to 7000 N that can be superposed with dynamic forces of up to ±1500 N. This superposition of periodic forces with a non-zero mean makes the actuator capable of applying realistic loading conditions like those experienced by machines during cutting processes. To characterize the performance of this actuator, linearized static and dynamic models are described. Since experiments with the actuator exhibit nonlinear characteristics, the linearized static model is expanded to include the influence of nonlinearities due to flow, leakages, saturations, and due to friction and hysteresis. Since all major nonlinearities are accounted for in the expanded static model, the dynamical model remains linear. Unknown static and dynamical model parameters are calibrated from experiments, and the updated models are observed to capture experimentally observed behavior very well. Validated models are used to tune the proportional and integral gains for the closed-loop control strategy, and the model-based tuning in turn guides appropriate closed-loop control of the actuator to increase its bandwidth to 200 Hz. The statically and dynamically characterized actuator can aid machine tool structural testing. Moreover, the validated models can instruct the design and development of other higher-performance electro-hydraulic actuators, guide the conversion of the actuator into a damper, and also test other advanced control strategies to further improve actuator performance. Full article

This work presents a new concentric design structure of a bypass magnetorheological (MR) damper with a serpentine flux valve type. In this design, the serpentine valve is installed not in the middle of the piston but on the bypass channel of the damper. However, to make it less bulky, the location of the valve installation is chosen to be in line with the cylinder axis, which is different from the common configuration of the bypass damper. With the proposed design concept, the performance flexibility of the bypass configuration and the compactness of the piston valve configuration can be accomplished. In this study, these benefits were demonstrated by firstly deriving an analytical model of the proposed MR damper focusing on the bypass concentric valve structure, which is vital in determining the damping force characteristics. The prototype of MR damper was also fabricated and characterized using the dynamic test machine. The simulation results show that the damping force could be adjusted from 20 N in the off-state to around 600 N in the on-state with 0.3 A of excitation current. In the experiments, during low piston velocity measurement, the on-state results from the simulation were generally in good agreement with the experimental results. However, with the increase in piston velocity, the deviation between the simulation and the experiment gets higher. The deviations are most probably due to seal frictions that were not accounted for in the model. The seal friction is probably dominant as the seals in the prototype need to be prepared for handling higher fluid pressure. As a result, the frictions are quite prevalent and significantly affect the measured off-state damping forces as well, where it was recorded ten times higher than the predicted values from the model. Nevertheless, although there were deviations, the dynamic range of the concentric bypass structure is still 1.5 times higher than the conventional structure and the new structure can be potentially explored more to achieve an improved MR damper design. Full article