ERC for Compact

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ERC for Compact Efficient Fluid Power

• Center Overview
• Fluid Power Society
• 25 January 2007

Mike Gust Industry Liaison Director University
of Minnesota
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What is fluid power?

• Advantages of fluid power
• Excellent power to weight/size ratio
• Capable of extremely large forces
• Flexible and relatively easy to control

• Current uses
• Heavy equipment
• Construction industry
• Off-road vehicles
• Manufacturing

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Why use fluid power?
Fluid Power is Unique. It has unparalleled
torque, power and bandwidth for the same weight
or volume. Example Power/Weight (kW/kg)
Pneumatic Motor 0.3-0.4 Hydraulic
Motor 0.5-1.0 Electric Motor 0.03-0.1 Fluid
power weight advantage 101 Reference I. L.
Krivts and G. V. Krejnin, Pneumatic Actuating
Systems for Automatic Equipment, Taylor and
Francis, 2006.

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• Fluid Power is Pervasive
• Used in aerospace, agriculture, construction,
  manufacturing, medical, mining and
  transportation.
• Over half of all industrial products have fluid
  power critical components almost all
  manufacturing uses fluid power.
• 3. Component sales are 12 billion (USA) and 33
  billion (worldwide). Systems sales are one to two
  orders of magnitude higher.

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Fluid Power is Growing
Source US Census Bureau Industrial Report for
Fluid Power, based on an annual Survey of US
manufacturers. 2005 includes NFPA estimates for
Nov/Dec. Estimated Growth for 2006 is a composite
based on several independent forecasts.
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• But fluid power has challenges
• Efficiency improvements required
• Further reductions in size and weight
• Noisy, leaky, difficult to use

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Vision The vision of the Engineering Research
Center for Compact and Efficient Fluid Power
(CCEFP) is to transform fluid power so that it
is compact, efficient and effective. This will
benefit humanity by significantly reducing energy
consumption and spawning whole new industries. A
coordinated research and education program will
facilitate this transformation.
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What is an ERC?

• A collaborative approach to research between the
  National Science Foundation (NSF), academia and
  industry whose
• Primary focus is on the definition, fundamental
  understanding, development, and validation of the
  technologies that will either
• Spawn whole new industries or
• Radically transform the product lines, processing
  technologies, or service delivery methodologies
  of current industries
• ERC innovations in research and education are
  expected to impact curricula at all levels
• Promote diversity of the scientific and
  engineering workforce
• Act as change agents for academic engineering
  programs and the engineering community at large.
• 42 total ERCs since mid 1980s25 currently
  active

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The role of an ERC
Fundamental research overlap w- academia
Applied technology Overlap w- industry
Fundamental Research
ERC
Industry New Product Development
Industry Production Support
Industry Adv. Tech.
Innovation Timeline
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ERC Class of 2006 Synthetic Biology Engineering
Research Center (SynBERC) UC-Berkeley
(Lead) Quality of Life Technology Engineering
Research Center (QoLT) Carnegie-Mellon
University (Lead) Engineering Research Center
for Compact and Efficient Fluid Power (CEFP)
Minnesota (Lead) Mid-Infrared Technologies for
Health and the Environment (MIRTHE) Princeton
(Lead) Engineering Research Center for
Structured Organic Composites (C-SOC)
Rutgers (Lead)
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ERC Organization
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ERC Organization
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ERC Academic Membership
Lead University University of Minnesota Core
Universities University of Illinois
Urbana-Champaign, Georgia Institute of
Technology, Purdue University, Vanderbilt
University Outreach Universities Milwaukee
School of Engineering, North Carolina AT State
University (HBCU). Outreach Institutions
National Fluid Power Association, Project Lead
the Way, Science Museum of Minnesota.

• The countrys best universities in fluid power.
• Nationally Ranked in engineering, mechanical
  engineering and related disciplines.
• World-class research universities.
• Comprehensive universities with opportunities to
  tap into other expertise as the center evolves
  (medical schools, science departments,
  specialized facilities, business schools, etc.)

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Full Strength Organizational Capacity

• Equipment and Infrastructure
• 25,000 sq ft of dedicated lab space
• Numerous cutting edge technology laboratories
  available within the university structure
  including MEMS and Nano.
• Currently (60) participating industry partners
  with existing labs

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Multi-disciplinary Teams acoustics (Cunefare,
Mongeau) biomedical engineering (Durfee,
Goldfarb, Hsiao-Wecksler)chemistry (Kaltchev,
Michael) computer-aided design (Ivantysynova,
Paredis) computer science (Paredis) education
(McCary-Henderson) engineering design (Barth,
Book, Durfee, Goldfarb, Ivantysynova) fluid
mechanics (Frankel, Loth) fluid power (everyone)
human factors (Book, Durfee, Jiang, Mountjoy,
Park) internal combustion engines (Kittleson)
materials (Gervasi, Mantell, Stelson)
manufacturing (Gervasi, Mantell, Stelson) MEMS
(Werely) system dynamics and control (Alleyne,
Barth, Book, Durfee, Goldfarb, Li, Lumkes,
Stelson)tribology (Bair, Ivantysynova,
Salant) New research initiatives will involve
collaborators from other fields available in the
participating universities.
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CCEFP ERC Strategic Thrusts
Efficiency Thrust is needed to reduce our
Nations dependence on imported fossil fuels and
benefit the environment. The energy savings pay
for the center many times over. Compactness
Thrust is needed to migrate fluid power
technology to human scale devices opening up
large opportunities for novel applications. This
will create entire new businesses and increase
the well-being of humanity. Effectiveness Thrust
is needed to realize the ultimate vision of fluid
power that is easy to use, clean and safe. No one
will use fluid power in the new applications
unless these problems are solved.
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Three Level Research Test Bed Diagram
Energy Efficient Excavator
Throttle-less Control
Digital PWM Valve
We will validate our research on targeted
platform systems
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ERC organization structure
Test Beds
Compact Crawler G-Tech
Compact Tools UMn
Excavator PU
sUV UMn
Orthosis U-ILL
IMM UMn
Thrusts
Efficiency
Compactness
Effective
Cross university approach
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Test bed champions
TB6 FP assisted orthoses prostheses
TB1 Excavator
TB4 Compact Rescue Crawler
TB2 Injection molding machine
TB3 small Urban Vehicle (sUV)
TB5 FP assisted hand-tools
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Industry Members
Newest Members
29. Master Pneumatic-Detroit, Inc.30. Mead
Fluid Dynamics 31. MICO, Inc. 32. Moog Inc. 33.
National Fluid Power Association34. National
Instruments35. National Tube Supply Co. 36.
NORGREN 37. Parker Hannifin Corporation 38. PHD,
Inc.39. PIAB Vacuum Products 40. Poclain
Hydraulics, Inc. 41. Prince Manufacturing
Corporation 42. Quality Control Corporation 43.
R.T. Dygert International 44. Ralph Rivera 45. RB
Royal Industries, Inc. 46. RohMax USA, Inc. 47.
ROSS Controls 48. Sauer-Danfoss 49. Schroeder
Industries 50. Simmetrix 51. Sterling Hydraulics,
Inc. 52. Sun Hydraulics Corporation 53.
SunSource 54. Tennant Company 55. The Toro
Company 56. Veljan Hydrair Private Limited
1. AAA Products International   2. Air Logic 3.
Aladco 4. Bimba Manufacturing Company 5. Bosch
Rexroth Corp. 6. Caterpillar Inc. 7. John Deere
Company8. Delta Computer Systems 9. Deltrol
Fluid Products 10. Eaton Corporation 11. Enfield
Technologies 12. Festo Corporation 13. Fluid
Power Educational Foundation 14. Gates
Corporation 15. Häglunds Drives Inc. 16. Haldex
Hydraulics Corporation 17. HECO Gear, Inc. 18.
Hedland Flow Meters 19. High Country Tek 20.
HUSCO International, Inc. 21. HYDAC22.
Hydraquip23. INA USA Corp. Schaeffler Group 24.
Kepner Products 25. LatchTool 26. Linde
Hydraulics Corp.27. G.W. Lisk Co., Inc. 28. Main
Manufacturing Products, Inc.
57. Donaldson Company58. MTS Corporation 59.
Shell Oil Corporation 60. Nexen group, Inc. 61.
TBD
NSF request to recruit new Aerospace and
Automotive members
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Master Pneumatic
National Tube Supply Company
HIGH COUNTRY TEK
Ralph Rivera
Member of the Schaeffler Group
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Scientific Advisory Committee
Hans Aichlmayr Sandia National
Laboratory Richard Burton University of
Saskatchewan Christine M. Cunningham Museum of
Science, Boston Kevin Edge University of
Bath Frank Fronczak University of
Wisconsin Lonnie J. Love Oak Ridge National
Laboratory Stephen Jacobsen University of
Utah Noah Manring University of
Missouri-Columbia Hubertus Murrenhoff
RWTH-Aachen Jan-Ove Palmberg Linköping
University Masayoshi Tomizuka University of
California-Berkeley A. Galip Ulsoy University
of Michigan
Distinguished council to help guide us
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Energy Importance

• Sector Energy cost/yr. Savings (10
  improve)
• Agriculture, Mining and Construction 28
  B 2.8 B
• Manufacturing (machine drives only) 42 B 4.2
  B
• Total 70 B 7.0 B
• Source U. S. Dept. of Energy, Annual Energy
  Review 2004, Report No. DOE/EIA 0384(2004)

Each 10 improvement in energy efficiency in
these sectors will result in a savings of 7
Billion/year.
Goal 1 Dramatic improvement in efficiency of
fluid power
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Quantification of energy savings

• Example 1 Excavator
• Assume typical load cycle in a load sensing
  system (Eggers, et. al, 2005)
• Loss due to throttling 18
• Pump loss 18
• Line loss 2
• Piston loss 2
• Useful work 60
• ERC research
• Eliminate throttling losses (1A,1E)
• Reduce pump loss by 30 (1B,1C)
• Reduce line loss by 30-40 (1D)
• Enable regeneration (1A, 1B, 1E)
• Efficient human interface (3A)
• 30 saving 1.15 billion/yr. for earthmoving
  equipment

100 units of energy
50-70 units of energy depending on whether load
cycle permits regeneration
Literature cited by SVT suggests that 30 of
actual work can be obtained from regeneration
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Energy Savings Transportation
Sector Energy cost/yr. Savings (10
improve) Transportation 240 B 24
B Sub-sector Energy cost/yr. Savings
(10 improve) garbage trucks 1.1 B 110
M buses 1.3 B 130 M passenger cars 100
B 10,000 M
Each 10 improvement in the efficiency of
passenger cars would save 10 Billion/year
GOAL 2 Develop fluid power hybrid vehicular
technologies that make passenger cars highly
efficient and have high performance.
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Industry Example

• Hydraulic launch assist (HLA)
• Parallel hybrid
• Regenerates 80 braking energy
• 30 fuel saving
• Significant reduction in emissions (50 of NOx,
  30 CO2)
• 280KW power 380kJ energy

HLA on a class 3 Ford F350 truck

• Weighs 250kg
• Occupies 200 Liters
• Too heavy and too large for passenger cars

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EPA Example
EPA UPS Hydraulic Hybrid Delivery Vehicle Program
70 percent better fuel efficiency (urban
driving) 40 lower CO2 emissions 1000 gallons of
fuel saved per vehicle annually 50,000 lifetime
savings per vehicle
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The Challenge 40 of Americans over 65 have
mobility impairments. There are no portable
powered devices to help them.
The Goal People with mobility impairment will be
assisted by powerful, portable devices that are
clean, quiet and safe.
The Solution Compact and Efficient Fluid Power
National Institute on Disability and
Rehabilitation Research (NIDRR)
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The Challenge State of the art humanoid robots
(Honda P3) can only operate for 20 minutes
without doing any useful work, but the market for
service robots is estimated to worth 10 billion
in a decade (Japan Gov. Report, March, 2005)
Woody Allen as Domesticon in Sleeper, 1973

• The Goal Everyone will be helped by robots. The
  robots will be intelligent and autonomous, but
  also powerful, untethered, quiet, safe and clean.

Honda P3 Robot
The Solution Compact and Efficient Fluid Power
R2D2 and C3PO in Star Wars, 1977
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Current Technology

• Battery-electric motor combination is too heavy
• Fluid power has high intrinsic power density
• However, overall system is not portable or
  un-tethered.

Apply Fluid Power
GOAL 3 Fluid power that is portable wearable
untethered autonomous capable of operating for
long periods without external energy sources.
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Barriers to Acceptability

• Barriers to the more widespread acceptance of
  fluid power
• 1. Difficult to use
• 2. Noisy
• 3. Leaky
• This prevents the more widespread use of fluid
  power.

GOAL4 Fluid power that is ubiquitous since it
is leak proof, quiet and easy to use (fast,
precise and intuitive).
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• New Applications and New Industries
• Products rescue robots, hazardous materials
  manipulators, space and underwater robots,
  service robots, medical and rehabilitation
  devices, wearable and compact tools for home and
  industry

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Thrust area I research projects Efficiency

• Efficient system configurations
• 1A1. Integrated algorithms for optimal energy use
• 1A2. Throttle-less control and regeneration
• 1E. On/off valve concepts for energy
  transformation and control
• 1F. Biomimetic approach for distributed fluid
  pressure generation, energy storage and control
• Efficient components
• 1B. Advanced/adaptive surface designs for pumps
  and motors
• 1C. Microactuators for active modification of
  surface topology in lubrication gaps
• 1D. Drag/leakage reduction via nano-texturing
• 1G. Engineered Fluids
• Blue Delayed project

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Thrust area II research projects Compactness

• Compact power source
• 2A. Chemo-fluidic hydraulic actuators
• 2B. Free-piston engine compressor
• Compact energy storage
• 2C. Compact energy storage
• Materials
• 2D. High pressure, light weight components using
  engineered materials
• Scaling and Integration
• 2E. Component integration for fluid power systems
• 2F. Dynamically scalable fluid power systems

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Thrust area III research projects Effectiveness

• Human factors
• 3A1. Multimodal human machine interfaces (HMIs)
• 3A2. Passified chemofluidic HMI control
• 3A3. Human performance modeling and user centered
  design
• Noise vibration and cavitation
• 3B1. Passive noise reduction in fluid power
  systems
• 3B2. Active noise controlof hydraulic pump noise
• 3C. CFD simulation of cavitating flows
• Tribology
• 3D. Leakage reduction in fluid power systems
• 3E. Prevention and management of contaminants
• Blue Delayed project

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New research direction Engineered Fluids

• Recent advances in long-chain polymer additives
  have created hydraulic fluids with a much higher
  viscosity index (less variation of viscosity with
  temperature).
• Test under realistic conditions show double digit
  improvements in efficiency.
• Research goals
• 1. Explore new additives (carbon nanotubes).
• 2. Tailor the fluid to the application
  (viscosity(pressure, temperature)).
• 3. Optimize fluid power components (including
  fluids) and systems.

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New research direction Increased Pressure

• Compactness requires increased power density
• Power Presssure x Flow
• Increased Flow required Increased Rotation Rate
  for Pumps and Motors leading to
• 1. cavitation and noise
• 2. decreased efficiency
• 3. reduced equipment life
• Solid material performance is well-known at high
  pressure, but fluid and fluid power component
  performance is less well-known.
• High Pressure Operation New Sub-thrust under
  compactness

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Supplemental research projects

• New Directions Engineered Fluids and High
  Pressure Operation
• Supplemental Funding Request (300,152)
• 1. Sealing and Liquid Property Investigation
  Applied to Hydraulics at High Pressure (expansion
  of 3.D Seal Modeling and Design) Scott Bair and
  Richard Salant (Georgia Tech)
• 2. Nanotube Additives for High-Pressure Fluid
  Power Systems (expansion of 1.G Optimized
  Engineered Fluids) Paul Michael (MSOE) and Eric
  Loth (UIUC)
• 3. High Pressure High Speed PWM Valve Operation
  (expansion of 1.E On/Off Based Control) John
  Lumkes (Purdue) and Perry Li (Minnesota)

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Major Accomplishments of the first five years

• Knowledge Base
• Detailed models of turbulence-cavitation
  interactions, cavitation noise and impact on
  performance
• Models of Elasto-Hydro Dynamic phenomena within
  high pressure thin films in nanoscale domain
• Biomimetic nano-surface features and carbon
  nanotube additives to reduce flow drag
• Models of flow phenomena in thin films with
  elastomeric-metallic interfaces to understand
  inter-asperity cavitation and asperity
  deformation
• Dimensionless dynamic design criteria
• High bandwidth control of catalytic chemical
  reactions
• Human performance models of multi-modal
  human-hydraulic interfaces
• New control theories for fluid power systems
• High-pressure behavior of fluids and components

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Major Accomplishments of the first five years

• Enabling Technologies
• Compact and efficient pumps and motors
• Throttle-less control (displacement control,
  on/off control)
• Energy regeneration
• Compact power supplies
• Compact energy storage
• Compact, light-weight, efficient, high-pressure
  components
• Engineered fluids
• High-speed on/off valves
• Noise and vibration control
• Human/machine interface
• Modeling, integration and optimization software
  for fluid power

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Major Accomplishments of the first five years

• Engineered Systems and Testbeds
• Excavator (TB1) Comprehensive system evaluation
  to demonstrate significantly improved efficiency
  through improved control (displacement control,
  on/off control, regeneration) and improved
  components (pumps, motors, fluids).
• Small Urban Vehicle (TB3) Comprehensive system
  evaluation to demonstrate significantly improved
  efficiency (as with TB1) and compactness. Compact
  energy storage is a critical enabling technology.
• Rescue Robot (TB4) and Orthosis (TB6)
  Comprehensive system evaluation to demonstrate
  compactness. Compact energy sources and component
  integration are critical enabling technologies.
• All testbeds Demonstrate improved effectiveness
  so that they are easy to use, quiet and leak
  proof.

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ERC Five Year Cost Sharing Model
Total Funding 21.71 Million
Industry (in kind)
0.66M 3.1
Industry (cash)
3.09M 14.2
University cost share
2.99M 13.8
NSF
14.97M68.9
Industry can leverage their investment by nearly
6 to 1!
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Membership overview

• Consider all the benefits
• Tremendous growth potential thru high value
  innovation approach
• Unparalleled leverage via NSF, university
  matching and industry members
• Future talent pool for your organizations
• Improve FPs image by fixing long standing issues

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Thank You