Undesired oscillations in hydraulic jack
Projects and Objectives
A hydraulic components manufacturer, upon reaching the testing phase of a new hydraulic actuator prototype for controlled lifting of variable loads, encountered significant oscillations during the load lifting process. To identify the causes of the issue, the company turned to BSIM and its simulation services.
Approach to the analysis
Thanks to BSIM’s experience in 0D/1D fluid dynamics simulation, the BSIM engineers created a model of the lifting system to accurately reproduce the entire load-lifting mechanism, including the mechanical components, the hydraulic system, and the external control system.
The client’s experimental data was used to calibrate the numerical model, thus creating a digital twin of the real system.
Once the numerical model was calibrated using the experimental data, the geometric issues leading to instability in load management were identified.
The simulations quickly revealed the problem: a suboptimal sizing of the vent orifices caused significant oscillations during the load-handling operation.
By leveraging the simulation, the most suitable geometry was determined to significantly reduce the perturbation phenomenon during lifting, thereby ensuring the proper functioning of the hydraulic jack. The model was then tested with various geometries until the optimal condition was achieved:
The modifications tested by BSIM were then discussed with the client, who decided to apply them to the existing physical prototype. The new experimental data, following the geometric modification of the orifices, closely matched what had been predicted by the 0D/1D CFD simulation, demonstrating a high degree of accuracy.
Conclusion
The modification was quickly implemented by the client who, as expected, was able to resolve the critical issue that had delayed the product’s deployment. For the future, it was decided to perform simulations of new prototypes in advance, even before they are physically produced, in order to shorten design and prototyping times and reduce operational costs.
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