Hydraulic Fluid Power Technology

Hydraulic fluid power systems produce unparalleled levels of power with tremendous flexibility and minimal size and weight requirements. Since 1947, Southwest Research Institute has helped industry and government develop specialty hydraulic systems, while identifying and resolving pneumatic and hydraulic fluid power problems.

SwRI offers services in:

Design

• Conceptual component design
• Computer-aided design
• Circuit design

Testing

• Performance
• Durability
• Response
• Wear

Analysis

• Solid marketing
• Finite element analysis
• Dynamic computer simulations
• Control system analysis

Systems integration

• Component selection
• System fabrication
• Electrical integration
• Control electronics development

Engineering activities are supported by comprehensive testing and support facilities:

• Dual dynamometer test stands
• Engine-driven test stands
• Small pump test stand
• Noise and vibration test facilities
• Environmental simulators
• Radioactive tracer wear test techniques
• High-pressure test/burst facilities

Design

The Institute designs hydraulic components for high performance, high efficiency, and long life. Using computerized solid modeling design systems, SwRI rapidly develops new designs that integrate advanced materials and processing techniques to optimize performance, minimize wear, and increase service life.

Using a computerized solid modeling CAD system, SwRI designed the complex internal porting of this prototype control valve.

Institute engineers designed and developed a retractable suspension system for a prototype high water-speed amphibious armored personnel carrier. The lightweight unit uses a compressible fluid as a spring with internal pressures up to 18,000 psi.

Testing

The Institute tests hydraulic components and systems to evaluate the performance and endurance of:

• Pumps
• Valves
• Actuators
• Motors (including high-speed, low-torque)
• Hydrostatic transmissions
• System accessories

Using computerized data acquisition and control, SwRI accurately measures component and system performance, both in the laboratory and in the field. Flexible facilities allow the Institute to design custom tests for equipment ranging from a small pneumatic hand tool to a hydrostatic vehicle transmission.

The Institute studies overall pump efficiency and pumping losses at various speeds, pressures, and temperatures. Automatic transmission pump and power steering pump efficiency variations can significantly affect vehicle fuel economy.

Analysis

Using computerized analysis tools, SwRI simulates components and systems to analyze problems, predict performance, and optimize designs. The Institute offers a variety of analysis techniques that minimize product development time and costs, such as:

• 3-D CAD solid modeling
• Finite element analysis
  • Thermal
  • Structural
  • Dynamic
• Transient component and system simulations
• Computational fluid dynamics analysis
• Probabilistic analysis
• Control system design and analysis
  • Classical and modern control theory
  • Fuzzy logic
  • Adaptive control
  • Neural networks

Using simulations of vehicle active suspension systems, SwRI develops control algorithms and predicts performance and power requirements.

Systems Integration

Combining the muscle of hydraulics with the flexible control of electronics, SwRI provides optimal hydraulic control systems. Using commercially available hardware or custom-designed electronic circuit boards and hybrid circuits, engineers develop systems to meet performance requirements as well as radio frequency emissions and susceptibility requirements.

An SwRI-developed computer-controlled, dual-path, hydrostatic transmission propels a prototype amphibious armored personnel carrier both on land and in water.

Additional Services

Institute engine and vehicle expertise is augmented by specialists in materials, fluids, experiment design, and data analysis.

Materials analysis and testing
Specialized laboratories support analysis of materials to diagnose failures and applications research in advanced materials and coatings.

Fluids analysis and research
Extensive laboratory tests provide detailed information about fluid conditions and properties. SwRI conducts standardized fluid wear tests and evaluates fluid filters for performance and durability. A state-of-the-art fuel and chemical processing facility processes and blends special fluids.

Experimental methods design
To determine hydraulic component and system parameters and characteristics, SwRI engineers prepare test schedules to replicate actual operating conditions. With fractional factorial screening and Taguchi techniques, experimental runs are minimized while maximizing the value of the data.

Data analysis
All data are examined for appropriateness, accuracy, calibration, and repeatability. The Institute applies statistical methods, such as response surface modeling and analysis of variance, to characterize component performance.

Institute engineers evaluate hydraulic component compatibility with a nonflammable hydraulic fluid.

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