Motion Control of Hydraulic Actuators In the Presence of Discrete Pressure Rail Switching

Conventional off-highway mobile machines are hydraulically actuated and have poor energy efficiencies. The goal to increase system efficiency and to reap the benefits of electrification have led to the creation of a novel Hybrid Hydraulic-Electric Architecture (HHEA) which could significantly increase efficiency, decrease the sizes and cost of electrical components, and maintain control performance. The key concept is to utilize a set of common pressure rails to provide the majority of power via the power dense hydraulics and to modulate that power by small electric components, which are less power dense, for precise control. The paper presents the motion control strategy for this architecture. The architecture presents a distinct challenge in that as the energy minimization algorithm selects different pressure rails, the system could experience large discrete jumps in pressures that impact control performance, especially when the electric components are torque limited. To meet this challenge, a passivity based back-stepping controller is used as the nominal controller between pressure rail switching events and a separate transition controller is used to deal with the pressure rail switching events. Two transition controllers are proposed, one uses the electric motor torque as the input, and the other also uses valve timing as a second input. For both transition controllers, a least norm control approach is used to steer the system states to the exact desired states at the end of the short transition period (~40 ms). The transition controllers are able to reduce the tracking error and the required electric motor torque, and hence achieve better control performance even with smaller electric components.