• Energy Research

The development of assistive lower-limb exoskeletons gains prominence for human load-carrying augmentation. Hydraulic transmission has attractive hydrostatic features and lower inertia at the end of human limbs. However, few hydraulic lower-limb exoskeletons were developed with low energy consumption and light weight. In this article, we introduce HyExo, a quasi-passive hydraulic exoskeleton that is built on a lightweight rotary cage valve (RCV) block with a fast response and low energy consumption of 1.55 W. Based on the RCV block, we propose an optimization-based regulator for joint energy distribution to harvest and release the hydraulic energy among joints during the stance phase. The interaction force model and control of the novel nonanthropomorphic structure are presented and evaluated. The load-supporting effect was investigated and validated through human subject experiments. The results show that with an assisting fluid pressure of 2.5 MPa, HyExo can transfer a mean force of 237 N to the ground. Meanwhile, the impact of wearing HyExo on gait is analyzed. The metabolic expenditure test shows that HyExo can slow the increasing rate in metabolic cost as load increases. Compared with a regular backpack, walking with HyExo to carry 30 kg of weight reduces wearers' metabolic energy expenditure by 7.8%.

AbstractPiezoelectric energy harvesting captures mechanical energy from a number of sources, such as vibrations, the movement of objects and bodies, impact events, and fluid flow to generate electric power. Such power can be employed to support wireless communication, electronic components, ocean monitoring, tissue engineering, and biomedical devices. A variety of self‐powered piezoelectric sensors, transducers, and actuators have been produced for these applications, however approaches to enhance the piezoelectric properties of materials to increase device performance remain a challenging frontier of materials research. In this regard, the intrinsic polarization and properties of materials can be designed or deliberately engineered to enhance the piezo‐generated power. This review provides insights into the mechanisms of piezoelectricity in advanced materials, including perovskites, active polymers, and natural biomaterials, with a focus on the chemical and physical strategies employed to enhance the piezo‐response and facilitate their integration into complex electronic systems. Applications in energy harvesting and soft robotics are overviewed by highlighting the primary performance figures of merits, the actuation mechanisms, and relevant applications. Key breakthroughs and valuable strategies to further improve both materials and device performance are discussed, together with a critical assessment of the requirements of next‐generation piezoelectric systems, and future scientific and technological solutions.

Abstract The conventional hydraulic drive system for a heavy-load mobile manipulator is usually operated under single mode, such that both inlet/outlet and potential energy losses are large to lower the energy efficiency. In this paper, a novel electro-hydraulic drive system is presented to improve energy efficiency. Extended control degrees of freedom are obtained utilizing the independent metering valve and electronic controlled pump. Then, multiple operating modes are carried out pertaining to the cylinder, valve, and pump. To achieve both optimal energy efficiency and precise motion tracking, both multi-mode switching and multi-variable controller are designed to accommodate with time-varying and uncertain load characteristics. As a consequence, the inlet, outlet, and potential energy losses can be decreased simultaneously. The experimental validation is conducted by using a three-joint manipulator in a 2 t excavator. A duty cycle of movement including all three actuators and covering full load quadrants is used to evaluate the efficiency improvement. Compared with the conventional load sensing system, the proposed multi-mode switching system using the pump pressure with valve meter-in control mode yields a 25.8% energy-saving ratio. Furthermore, the pump flow with valve mete-out control mode yields a 35.3% energy-saving ratio. Using this combined control mode, higher efficiency can be obtained due to the minimum inlet losses, but faster dynamic response together with higher overshoot will appear. It is proved that the energy efficiency is improved, while the motion tracking performance is not degraded by introducing the multi-mode switching.

AbstractThe need for wireless condition monitoring and control of hydraulic systems in an autonomous and battery‐free manner is attracting increasing attention in an effort to provide improved sensing functionality, monitoring of system health, and to avoid catastrophic failures. The potential to harvest energy from hydraulic pressure ripples and noise is particularly attractive since they inherently have a high energy intensity, which is associated with the hydraulic mean pressure and flow rate. This paper presents a comprehensive overview of the state of the art in hydraulic pressure energy harvesting, which includes the fundamentals of pressure ripples in hydraulic systems, the choice of electroactive materials and device structures, and the influence of the fluid–mechanical interface. In addition, novel approaches for improving the harvested energy and potential applications for the technology are discussed, and future research directions are proposed and outlined.

With the compact circuit layout and small size, hydraulic manifolds sometimes cause high pressure loss. The purpose of this paper is to investigate the pressure loss under different circumstances with various geometry features and present solutions to reduce pressure loss. The pressure loss performance is evaluated by both experimental and numerical methods. Verified by the experiments, the numerical simulations are qualified to depict the correct trend of the pressure drop. After the basic analysis of traditional passages, three novel forms are proposed, which are very hard to be manufactured by a common method. Furthermore, the geometrical features are selected optimally by means of full factorial experiments to balance the pressure loss and space requirement. Moreover, taking advantage of 3D printing, it is possible to build the passages in novel forms which are beyond the capacity of conventional manufacturing. Results show that the pressure loss can be reduced considerably by adopting a smooth transition, where the reduction can reach up to 50%.

AbstractHydraulic fluid power systems are essential for a range of engineering applications such as transportation, heavy industry, and robotics. The scale of the industry is such that hydraulic pumps are estimated to account for 15% of all the energy consumption in the European Union and yet the average efficiency of fluid power systems is only 22%. The digitalization of hydraulic systems offers significant advantages in terms of energy efficiency, performance, reduced maintenance, and automation. However, this requires advances in the integration of smart sensing technologies to provide real‐time feedback on the operation and health of hydraulic components. This review details developing trends in hydraulic fluid power research and provides an overview of progress related to the digitalization of these systems and their integration within an Industry 4.0 framework. The fundamentals of relevant sensor technologies and innovative approaches for integrating sensors into hydraulics systems are discussed. Methods to deliver power to the sensors and associated electronics through harvested pressure ripples are also reviewed. An outlook with respect to future directions in this field is given, including an assessment of the potential for exploiting advanced manufacturing technologies, in particular additive manufacturing, to facilitate successful sensor integration into hydraulic fluid power systems.

The switched inertance hydraulic system (SIHS) is a novel high-bandwidth and energy-efficient digital device which can adjust or control flow and pressure by a means that does not rely on throttling the flow and dissipation of power. An SIHS can provide an efficient step-up or step-down of pressure or flow rate by using a digital control signal. In this article, analytical models of an SIHS in a four-port high-speed switching valve configuration are proposed, and the system dynamics and performance are investigated theoretically and experimentally. The flow responses, system characteristics and power consumption can be predicted effectively and accurately by using the proposed models, which were validated by comparing with experiments and with numerical simulation. The four-port configuration is compared with the three-port configuration, and it is concluded that the former one is less efficient for valves of the same size, but provides a bi-direction control capability. As bi-direction control is a common requirement, this constitutes an important contribution to the development of efficient digital hydraulics.

Pressure and performance requirements of axial piston pumps and the proportion of churning losses in axial piston pumps increase significantly with increasing speed. To investigate the primary distribution of churning losses in axial piston pumps at various ranges of speed, a test rig was set up in which other friction losses can be eliminated, thus making it possible to investigate the net churning losses in an axial piston pump. The influence of the rotating cylinder block and pistons on churning losses is analyzed based on a qualitative evaluation of the various fluid flow regimes at different test speeds in an axial piston pump. The analytical results indicate that pistons have less influence on churning losses than the rotating cylinder block beyond the critical speed in axial piston pumps, because the total energy dissipation transforms laminar viscous friction losses into turbulent shear stress losses. It is concluded that more attention should be given to the effect of the rotating cylinder block on churning losses in axial piston pumps at high rotation speed.