NPD Lead Time Reduction:
Hydraulic Cylinder Cushioning
System Design-
A Case Study
Contents
S. No TITLE Slide #
1 About WIPRO Group 3
2 NPD Impact - Cost & Time 23
3 Cushioning in Hydraulic Cylinders 26
4 Conventional Cushioning Tests 31
5 Unconventional Cushioning Tests 35
6 Using Technology for Cushioning 37
Design
7 Summary 51
8 Q&A 53
© confidential 2
Values we live by
About
Be passionate about clients’ success Wipro
Treat each person with respect
Be global and responsible
Unyielding integrity in everything we do
© confidential 3
Wipro 1
2
Wipro Enterprises (P) Limited Wipro Limited
IT PRODUCTS &
WIPRO INFRASTRUCTURE
SERVICES WIPRO CONSUMER CARE & WIPRO LIMITED
ENGINEERING LIGHTING
IT
• Personal Care products • IT
• Hydraulic Cylinders
BPO • Aerospace • Wellness products • BPO
• Home Care Products • R&D Services
R&D •Services
Additive Manufacturing
• Domestic & Commercial • Consulting Services
• Water Treatment Lighting and switches
Consulting Services
• Automation Solutions • Modular Office Furniture
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Wipro
Infrastructure
Engineering
About Us
Wipro is a multi-business group headquartered in Bengaluru, India
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Wipro Infrastructure
Engineering
40+ 2000+ 15
Years of Global Workforce Manufacturing
manufacturing facilities across 4
excellence continents
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Aero structures
Aerospace
Landing Gears
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Aerospace
Dedicated manufacturing facilities for Facilities and supply chain partners Transfer of technology agreement
Actuators, Aero structures and Precision certified by various global players such with CESA-Spain (a subsidiary of Airbus
Engineered Components as Boeing, Lockheed Martin, Messier group)
Bugatti Dowty, UTAS, Liebherr and
CESA
Long term agreements in place with leading OEM’s
- Boeing, IAI, Lockheed Martin, Northrop Grumman
and Global Tier-1 Suppliers for development and
manufacture of Precision structural parts, Landing
gear and Power Door Opening Systems actuators ISRAEL
and Utilities USA Haifa
Everett
INDIA
Bengaluru
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Additive
Manufacturing
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Wipro 3D
Leading provider of metal additive manufacturing solutions and
services
Additive Manufacturing Solutions
• Additive Manufacturing Consulting: Design & Adoption • Research & Development Solutions
• Prototyping & Manufacturing Services • Set Up & Operations of Captive AM Centres
Industry Segments
• Aerospace • Healthcare • Oil and Gas • Industrial
• Space • Automobile • Defence • Nuclear
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Water
Treatment
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Wipro Water
Leading system integrator providing highly customized water
solutions for diverse and large scale industrial water requirements.
500+ 350+ 25+
Global Projects Industry
Customers Executed Segments
Product portfolio
• Wastewater Treatment and Recycle System • Desalination System
• Storage & Distribution System • Pre-treatment (Clarification/Filtration)
• Microbial Reduction • Zero Liquid Discharge Solutions
• Oil & Water Separator System • Sustainable & Decentralized water treatment system
• Cooling Tower Management System • Post Water Treatment System
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Automation
Solutions
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Automation Solutions
End-to-end Industrial Automation Solutions that enable companies
in the discrete manufacturing sector to be automated, digitized and
smart.
Factory Automation Smart Factories
Integrated Hardware Solutions Industrial IT Solutions
Design Smart
Automation
Solutions
Smart Products Smart Sensors
IoT and Telematics Solutions In-built processors & analytics
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Joint
Venture
Wipro Kawasaki
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Wipro Kawasaki
Wipro Kawasaki Precision Machinery Pvt Ltd. is a joint
venture between Kawasaki Precision Machinery Company
and Wipro Infrastructure Engineering to manufacture
hydraulic pumps for excavators in India
Products
Hydraulic pumps for 7 – 20 tons excavators
Capacity
8000 pumps/year
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Hydraulic Cylinders
and
Solutions
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Product Range
Single and Double Acting Cylinders
• Bore 25 mm to 500 mm
• Stroke Up to 10,000 mm
• Working Pressure Up to 400 bar
Suspension and Hoist Cylinders
• Tonnage Up to 100 T
• Application Off Highway Trucks, Gas Hydraulic
System for Articulated Haulers
Telescopic Cylinder/Kits For Tippers Industrial Hydraulics
Custom designed Hydraulic Cylinders and Systems
• Front End Tipping Up to 6 Stages
• Under Body Tipping 2 – 11 Stages • Bore ID 200-500 mm
• Application Tonnage Up to 90 T • Rod OD 100-250 mm
• Mounting Types Eye type, Cover tube, Trunnion type • Stroke 2000-8000mm
• Accessories for Kits Pumps, Valves, tanks, Hoses • Operating pressure Up to 250 bar
9
Hydraulics for every application
Construction & Earthmoving Material/Cargo Handling & Forestry Farm & Agriculture
• Excavator (Mini, Midi and Large) • Loader Cranes • Harvester
• Backhoe Loader • Forestry Equipment • Sprayer
• Wheel Loader • Container Handler • Planter
• Motor Grader • Fork Lifts • Tractor Steering and Attachments
• Dozer • Tail lifts • Sugarcane Transporter
• Dumper • Hook Lifts and Refuse Collector
• Tele Handler
• Aerial Works Platform
Truck Hydraulics Mining & Special Applications Industrial Hydraulics
• Front End and Under Body Tipping Gears • Underground Haulers and Loaders • Process plants (steel, aluminum and others)
• Truck Steering • Surface Drill Rigs • Stationery mining equipment
• Cabin Tilt Cylinders and Latches • Windmills • Sluice and dam gate cylinders
• Car Carrier • Defence Applications • Bulk material handlers - stacker re-claimer
• Refuse Trucks • Hydraulic power plants
• 3 Way Tipping System
• Aggregates
We manufacture more than 2 million cylinders annually!
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Global Reach
EUROPE
Pernio – Finland
Europe Bispgarden – Sweden India
Ostersund – Sweden
Rm Valcea - Romania
Pernio – Finland Bengaluru
• Forestry • Construction and
• Mining Earthmoving
• Demountable Truck Tipping
Solutions
USA • Tech Centre and
Protoshop
Chambersburg
INDIA Hindupur – 1
Ostersund – Sweden Bengaluru • Material Handling
• Material/Cargo Handling Chennai • Truck Tipping Solutions
Hindupur (Plant 1) • Aggregates
• Forestry
Hindupur ( Plant 2)
Bispgarden – Sweden
• Material/Cargo Handling
Hindupur – 2
• Feeder plant for piston
BRAZIL rod manufacturing
Piracicaba
• Chrome plating
Skelleftea – Sweden
• Tech Centre and Protoshop
Chennai
• Farm and Agriculture
Rm Valcea – Romania Construction and
• Material Handling Earthmoving
• Construction and Earthmoving
USA Brazil
Chambersburg Piracicaba
• Material Handling • Farm and Agriculture
• Construction and Earthmoving • Construction and Earthmoving
• Aerial Works Platform
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Customers
Construction and Material/ Cargo Truck Hydraulics Farm and Agriculture
Earthmoving Handling and Forestry Solution
• Caterpillar • Cranab • Ashok Leyland • AGCO
• CNH • Haulotte • Bharat Benz • Carraro
• Deere Hitachi • Hiab • Dautel • CNH
• Escorts • HMF • Geesink Norba • Kubota
• Hyundai • JLG • lstrail • Mahindra and Mahindra
• JCB • John Deere • KH-Kipper • Vaderstad
• Kobelco • Kalmar • Mahindra and Mahindra • Valtra
• Kraneks • Kion Group • MAN
• Kubota • Kobelco Cranes • NTM Mining and Special
• Mahindra and Mahindra • Komatsu Forest • SAWO Applications
• Wacker Neuson • Komatsu Forklift • Sorling llsbo
• Sany • Liebherr • Tata Motors
• Tata Hitachi • Manitou • VECV • Epiroc
• Terex • Multilift • Volvo • Sandvik Mining and
• Volvo • Ponsse • Walser Construction
• TIL
• Toyota Material handling
• Zepro
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NPD
Lead Time Reduction:
Hydraulic cylinder cushioning system design-
A Case Study
NPD Lead time & Costs
COSTS
TIME
© confidential 23
Need for cushioning
• High pressure, fast actuations using cylinders in opposing directions causes
vibrations in the machine elements
• To overcome this there is a need to decelerate the cylinders
• This is done by oil flow restriction and is called cushioning/damping
• This restriction of flow causes pressure spikes and its own vibrations
• Hence there is a need to ´engineer an optimal cushioning design´ with
manageable pressure spike & satisfactory cushioning
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Cushioning systems
Cushioning in Excavator Cylinders
ARM Cylinder
BUCKET Boom Cylinder
Cylinder
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Cushioning concept for Excavator in extension
(1) High pressure in this (4) Orifice for relief Low pressure in this
chamber, the cushioning pressure chamber, oil goes to tank
bush keeps on touching
in piston rod face
ROD END
(2) In this moment
starts the cushioning
(3) Metalic sealing
between faces
Cushioning length
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Cushioning components details
(1) Cushioning Clearance= (A-B)/2
(2) No. of Notches
Head End Cover
Cover ID
(4) Notch Angle (5) Orifice hole size
(3) Notch Length
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Cushioning concept for Excavator in retraction
(3) Orifice for relief (2) The oil flows in
pressure clearance causing
deceleration
CAP END
(1) In this moment
starts the cushioning
Cushioning length
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Cushioning components details
(1) Cushioning Clearance= (A-B)/2
Cap End Cover
Cover ID
(3) Notch Length
(5) Orifice hole size
(4) Notch Angle
(2) No. of Notches
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Conventional cushioning tests
Cushioning design-How is it being done now?
• We saw that cushioning system design is a complex part of the hydraulic cylinder
design
• This design process involves, design and manufacture of various pins and bushes
as per design calculations and design experience
• So different test cylinders with these combinations are manufactured and tested
on customer machines
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Cushioning Test on an actual machine before design
freeze • The test cylinders are built with a special port so that
the pressure spikes can be measured during the
operation of the cylinder
• Different PIN and BUSH combinations are tried out
• The performance feedback is evaluated and design is
finalized or sometimes there is a need to try out
different combinations before the design can be
finalised
1029 Bar
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Cushioning design-How is it being done if the
Customer’s machine is not developed yet?
• We just saw that cushioning system design needs an actual machine for testing
• What if, the machine is under development and is not yet ready?
• Well, one option is to develop a TEST RIG that stimulates the machine KINEMATICS
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Unconventional cushioning tests
Cushioning test on a laboratory test rig
• This TEST rig design and manufacture took 6 months and costed appox
USD 60.000,00
• It is evident that this COST and TIME are avoidable
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Cushioning design-First time right
Cushioning design-Using a SOFTWARE?
• We have seen the traditional trial and error design of the cushioning system. This
needs the actual machine to have been developed and available
• We have also seen that if a real machine is unavailable, then a TEST RIG would
have to be developed, which again is time consuming, needs test rig design
competency and is prohibitively expensive
• Using a SOFTWARE that can take in all the mechanical and hydraulic system
INPUTS and calculate and deliver the OUTPUT for the design of the cushioning
elements would be an interesting proposition!
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Cushioning design elements
Cushioning Performance for any Cylinder depends on following
parameters in equipment :
• Cushioning component dimensions i.e.: Cushioning bush notch angle,
notch length, number of notches, cushioning clearance, orifice hole
diameter mainly;
• Equipment kinematics; structure weight, inertia.
• Hydraulic Parameter i.e.: Working pressure, speed of the cylinder rod.
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Wipro’s R&D & LINKOPING UNIVERSITY collaboration
• Prof. Petter Krus’s team and Wipro are working on a DAMPING software
• The following slides will show the glimpse of the work
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Stage 1
xv1
2
d1 d 2 d1 d 2 2
A x p s1
2 2
( s s ) tan
2
x p s1
2 d2
d1 1 3
2
d1
2
( s s ) 2
d1 1 3 x p s1
2
s3
s2
s1
xp
Stage 2
xv1
A
d12 d x2
d12 d1 x p s3 sin 2
4 4
(2d1 ( s1 x p ))( s3 x p )
4
s3
s2
s1
xp
2
1 ( s1 s3 ) cos 2
dh x p s3
2 2
Stage 3
s4
s3
s2
s1
xp
Nominal behaviour & Sensitivity to clearance
tolerances
Pressure sensitivity to viscosity (0.1-0.4 Pa s) & Mass
(1T to 5T)
Velocity Sensitivity to Expansion of cushioning
restrictor diameter (1.5- bush
3mm)
t dp
2t
/ E
c d
d di
c d2 p
r 1.6591012 p
2 4Et
with p 6107 Pa yelds:
r 0.09952103m
This is more than the nominal
clearance (0.0365mm).
Squeeze effect and only partial
pressure loading will prevent
damage, but it is likely to seal off
the passage near end stroke,
leaving the orifice to define the
flow/speed in the final
stagesbefore impact.
Effect of eccentricity
2
rc 3 e
q 1 p
6 L 2 c
c router rinner
If e c
2
e 3e
1 2.5
2c
This means that flow can be 2.5 times higher
than expected.
rheq 3 rh3
q 2.5
6 L 6 L
heq h 2.51/3 h 1.36
So this can be translated into a 1.36 times larger
equavalent symetric slit
Closest fit (with parameters in tolerance range)
Clearance =
0.06mm
Restrictor
diameter = 2mm
Notch angle =0.3
deg
Nominal Areas (Notch-blue, clearance-red)
Current status of this development
• The software, which runs on the HOPSAN platform at Linkoping University, is
tested for the ARM & BUCKET cylinders of a 20T excavator
• More work needs to be done to fine tune it for the BOOM cylinder
• And then to expand this for the different machine categories and test them out
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Summary & Conclusion
Summary & Conclusion
• NPD is the growth engine for a company, therefore it must be quick and cost
effective
• The case of a simple cushioning system design for a hydraulic cylinder, using the
traditional methods, is time consuming and expensive
• There is a clear need for a DAMPING SOFTWARE that can help with an OPTIMAL
design
• The benefits of such a software driven design would help with a FASTER &
CHEAPER NPD
• Prof Krus and his team are working with Wipro in Sweden to validate this
• This computer modelling space has an enormous research potential for the future
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©
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