Design A Novel Efficient Tube Bender

Design of a Novel Energy Efficient
Hydraulic Tube Bender Circuit
-Forming Machines-
Dr. Nader Nabil
Content
Abstract .1
Introduction .2
Conventional Hydraulic Tube Bender .3
Energy-Saving Controll Scheme .4
Modeling, Simulation results and Discussion .5
6. Conclusion
Content
Abstract .1
Introduction .2
6. Conclusion
A Conventional Energy Efficient
Hydraulic Tube Hydraulic Tube
Bender Circuit Bender Circuit
1. Sequence of the 1. Modification of

steps required to work conventional
the machine. Hydraulic circuit.
2. Design the suitable ” component ”
Hydraulic Cylinder. 2. Modeling.
3. Demanded Pressure 3. Simulation via
Of Working cycle. Matlab/Simulink &
“ Supply the H.C with pressure
liquid via an electric motor DSHplus.
driven hydraulic pump”
Content
Abstract .1
Introduction .2
6. Conclusion
Content
Abstract .1
Introduction .2
6. Conclusion
Conventional Hydraulic Tube Bender
The typical working cycle of hydraulic
tube bender
The actions are requested in the motion of hydraulic cylinder:
1. Supply the Hydraulic Circuit continuously with pressure liquid.
(via an electric motor driven hydraulic pump),
2. Limit the load of the cylinder. (Pressure Relief Valve),
3. Control the direction of movement of the cylinder. (Directional valve).
Circuit Diagram Of a Conventional
Hydraulic Tube Bender
Demanded Pressure in a Working Cycle
Q = A*V , t =Stroke/V
Content
Abstract .1
Introduction .2
6. Conclusion
Instead of
The conventional fixed displacement hydraulic pump, -

the new hydraulic tube bender utilizes an internal
gear pump with AC servomotor as its driving power
.source
In the new energy-saving hydraulic circuit, the use of -
conventional pressure relief valve is no longer
necessary since the demanded flow-rate and pressure
output can be precisely obtained by continuously
.changing the speed of the AC servomotor
Fixed-Displacement Pump
Q = Vp * n
Vp =Vg : Pump Displacement (cc)
Motor Frequency-n
n : Rotational Speed of Motor (rpm)
Ac Servomotor Vs Electric Motor
Saving-Energy
Up To ? %
Content
Abstract .1
Introduction .2
6. Conclusion
Energy-saving control scheme
The First one is load-sensing control strategy

The Second one is constant pressure control strategy
“Sliding-mode control
Vs
Fuzzy sliding-mode control ”
There are four procedures involved in the implementation of a fuzzy sliding mod controller,
1. Fuzzification “ s= X1 + X2 “
The error signal, e(k), and the error signal change, 􀇻e(k), are denoted by x1 and x2
respectively, that is
x1 = e(k) = PSset – Ps (1)
x2 =􀇻e(k) = e(k) - e(k-1) (2)
2. Inference “ s is proportional to u “
3. Defuzzification “ transform control signal into exact control output. “
4. Determination of scaling factors, GS and GU
“ s is multiplied by Gs=]-1,1 [, u is multiplied by Gu={ -10 to 10 } v.”
Scheme of the proposed “fuzzy sliding-mode control”

A simplified model for a single-acting hydraulic cylinder
Content
Abstract .1
Introduction .2
6. Conclusion
If the internal and external leakages of the cylinder are both negligible
Finally, the equation of motion (Force balance)
b newton’s friction coefficient (N s/m)

FL the load disturbance
(disturbances that drive the process away from its desired behavior)
Modeling, Simulation results and Discussion
• Two commercial software packages, the Matlab/Simulink

and DSHplus , are chosen as simulation tools.
The volumetric flow-rate output of the hydraulic pump is given by
Vp pump displacement􀄡(cc)
n reference rotational speed input􀄡(rpm)
In practice, the time constant, T, can be derived from the data sheet of the AC
.servomotor and is estimated to be 50 ms
The power consumption of the pumping unit can easily be calculated
by the following equation
To double check the validity of the mentioned modeling,
MatLab/Simulink model DSHplus model

Simulation cylinder displacements of the main
pushing unit
(a) MatLab/Simulink results (b) DSHplus results
Simulation actuating pressure curves of the main
pushing unit
(a) Matlab/Simulink results (b) DSHplus results

Simulation results of power consumption between two utilized closed-loop control strategies for
the main pushing cylinder
Content
Abstract .1
Introduction .2
6. Conclusion
Conclusion
Thank You
Presented by:
Shrouq Gamal

Design A Novel Efficient Tube Bender

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Design A Novel Efficient Tube Bender

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Design of a Novel Energy Efficient

Hydraulic Tube Bender Circuit

1. Sequence of the 1. Modification of

The conventional fixed displacement hydraulic pump, -

The First one is load-sensing control strategy

Scheme of the proposed “fuzzy sliding-mode control”

Finally, the equation of motion (Force balance)

b newton’s friction coefficient (N s/m)

• Two commercial software packages, the Matlab/Simulink

The volumetric flow-rate output of the hydraulic pump is given by

To double check the validity of the mentioned modeling,

MatLab/Simulink model DSHplus model

(a) Matlab/Simulink results (b) DSHplus results

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