FACULTY OF ENGINEERING, ARTCHITECTURE & BUILT ENVIRONMENT

Lab Report 3
EK409, Mechatronic Lab VI, Fluid Power & Drives Lab
May - August 2020
Experiment 3:
Part 1 Power-Assisted Steering Mechanism
Part 2 Injection Molding Actuation System

Name ID Course
1) Wong Wei Hao 1001746444 B.Eng (Hons)
2) Wong Wei Herng 1001746821 Mechatronic
3) Gabriel Wong Jung Yit 1001747052 Engineering
4) Choy Melvern 1001746771 (HYEK)
5) How Cheng Yang 1001746720
 TABLE OF CONTENTS

1. Introduction 3

2. Objectives 6

3. Safety Measures and Precautions 6

4. Apparatus and Material 6

5. Methodology 7

6. Results and Discussion 8

7. Conclusion 20

8. Reference 21

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Introduction

Part 1: Power-Assisted Steering Mechanism

In Malaysia, there are more than 31.2 million registered motorized vehicles on road, while most

of it being residential cars. Cars are momentous in the modern world as one of the most

convenient and fastest way to travel between medium to long range distance while being safe.

However, driving on the road used to be hectic before the hydraulic power-assisted steering rack

changed the whole industry.

A hydraulic power-assisted steering system includes a steering fluid reservoir (the source

in the circuit) that stores the fluid, steering pump that pulls the hydraulic fluid from the reservoir

and pressurizes it before pushing it into the cylinder chambers; a rotary valve that is sensitive

towards fluid flow and helps redirecting the fluid either into the steering rack, or back into the

steering pump, and lastly, the two cylinders in the hydraulic chambers.

As the fluid pump pressurizes the fluid from the reservoir and directing it into the

chamber, the two cylinders will be filled up with the fluid and the pressure presses against both

pistons in the cylinders. When there is more steering fluid in one of the cylinders, it creates

greater pressure, a pressure difference across the chamber is formed and it pushes the piston

harder and creating torque that directs the wheel to the opposite direction (left cylinder to right,

right cylinder to left). This is the essence of how a hydraulic power-assisted steering mechanism

works in a car.

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 The steering rack of a hydraulic power-assisted steering system.

Part 2: Injection Molding Actuation System

Unlike a power-assisted steering mechanism that aids in a vehicle, the injection molding

actuation system is more important in the manufacturing industry, especially in deformable,

molten ingredients manufacturing. Injection molding is a sophisticated manufacturing process in

which the manufactured part is done by injecting molten materials (polymers, metals) into a

fixed mold. It allows rapid manufacturing in production due to its simplicity and efficiency that

requires lower cost in manufacturing.

The injection molding actuation system is the mechanical part of the entire injection

molding system. First, the materials (plastics or metals) are connected to the injection system

with a hopper (a small reservoir) and is fed into the system with gravitational pull and by a screw

barrel connected to a hydraulic motor in the system. The materials are either heated to molten

state before entering the hopper or is being heated now as it is entering the screw barrel and flow

into the fluid line. There are two piston cylinders, namely the injection and the carriage piston.

Both cylinders are connected to form a push-pull movement during the process. When the mold

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opens, the carriage piston pulls the drilling system to close the mold before the injection piston

pushes the drilling screw forward to pressurizes the molten material into the mold.

The injection molding actuation system.

In this experiment, both systems are being tested and studied by manipulating their

variables and observing the changes in the result generated. Discussion will be carried out to

identify the reasons causing the changes in data as compared to the default system.

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Objectives

By the end of this laboratory session, the students will be able to:

- Simulate the power-assisted steering mechanism and injection molding actuation system.

- Understand the working mechanism of the systems, and their applications in real-life

scenarios.

- Making changes to the systems and allowing the system to adapt to applications.

Safety Measures and Precautions

- Behave in the laboratory by following the regulations, do not eat in the laboratory, do not

run and always wear a suitable attire with lab coats etc.

- Make sure the computers used to conduct the laboratory works are fully functional and

installed with the applications required, such as MATLAB with sufficient features.

- Do not attempt to modify the source codes of MATLAB application.

- Avoid using the counterfeit copy of MATLAB software found on random internet source.

It is illegal and could be sentenced to punishment.

Apparatus and Materials

- MATLAB R2020a, the latest version of the MATLAB software available.

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Methodology

1. “Power-Assisted Steering Mechanism” was searched in Simulink examples.

2. The model of the system was applied in Simulink.

3. The initial pressure plots in cylinder and counterbalance valve were observed and

recorded.

4. Then, 4 distinctive variables were changed, and the pressure plots for cylinder and

counterbalance valve were observed and recorded again. The outcome was discussed.

5. Repeat Step 1 to Step 4 for the “Injection Molding Actuation System”.

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Results and Discussion

Part 1: Power-Assisted Steering Mechanism

The circuit diagram of power-assisted steering mechanism.

Manipulated variables:

1. Relative amount of trapped air (From 0.005 to 0.1)

2. Hydraulic fluid (Oil-30W to water)

3. Steering velocity (Shown in result and discussion)

4. Cylinder piston area A and B (From 9.1cm2 to 5cm2)

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Default System Altered System

Cylinder pressure and Steering Wheel Angle Cylinder pressure and Steering Wheel Angle

with Relative amount of trapped air = 0.005 with Relative amount of trapped air = 0.1

Steering Wheel Torque and Steering Wheel Steering Wheel Torque and Steering Wheel

Angle with Relative amount of trapped air = Angle with Relative amount of trapped air =

0.005 0.1

Discussion: In real-life application, air bubbles in power-assisted steering system is dangerous

for drivers as it causes instability and poses a threat to the driver if it occurred during making a

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turn on the road. The relative amount of trapped air is adjusted from 0.005 to 0.1 to simulate

the situation. With the amount of trapped air increase, the efficiency of piston in building

pressure is much lower as the pressure generated is first used to overcome the air pressure of

air bubbles before creating useful torque to help of the steering. However, the amount of

trapped air bubbles is too high (0.1) and it completely disrupted the operation of the power-

assisted steering system, as shown in the plot of cylinder pressure and steering wheel torque.

Do notice that the power assisted steering mechanism somehow only take effect at the last part

of the process as shown in the steering wheel torque plot, and it required much more torque to

effectively assist the steering. This shows how dangerous is trapped air in power-assisted

steering or any hydraulic system in a vehicle such as braking system too.

Cylinder pressure and Steering Wheel Angle Cylinder pressure and Steering Wheel Angle

with Oil-30W as hydraulic fluid with water as hydraulic fluid

Steering Wheel Torque and Steering Wheel Steering Wheel Torque and Steering Wheel

Angle with Oil-30W as hydraulic fluid Angle with water as hydraulic fluid

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b

Default steering velocity graph Altered steering velocity graph

Cylinder pressure and Steering Wheel Angle Cylinder pressure and Steering Wheel Angle

with default steering velocity. with altered steering velocity.

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Steering Wheel Torque and Steering Wheel Steering Wheel Torque and Steering Wheel

Angle with default steering velocity. Angle with altered steering velocity.

Discussion: Through changing the steering velocity, it alters the steering wheel angle as

velocity includes direction of the motion as well (the altered direction shows a lean on righter

angle). And through the change in wheel angle, the cylinder pressure react to it by having

higher pressure on the left cylinder, and lower pressure on the right cylinder, to increase the

torque generated on the left to help steering to the right as shown in the cylinder pressure and

steering wheel angle graphs. In the steering wheel torque graph, it is noticed that the power

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steering system has managed to overcome and provided sufficient torque to aid the steering

despite the great change in wheel angle.

Cylinder pressure and Steering Wheel Angle Cylinder pressure and Steering Wheel Angle

with Cylinder piston area A and B = 9.1cm2 with Cylinder piston area A and B = 5cm2

Steering Wheel Torque and Steering Wheel Steering Wheel Torque and Steering Wheel

Angle with Cylinder piston area A and B = Angle with Cylinder piston area A and B =

9.1cm2 5cm2

Discussion: The overall trending of the graphs is the same with all higher peak values and

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 average value. With the surface area of the cylinders decrease by almost half of the original

area, according to the Pascal’s Principle, P = F/A, with lower surface area comes with higher

pressure exerted on the surface, and this is proven in the cylinder pressure graph, where the

average value of cylinder pressure is higher. However, it is shown that lower torque is needed

to assist the steering and still achieved stability in the system as shown in the steering wheel

torque graph, when the steering wheel velocity is the same for both systems. The reason is

remained uncertain even after researches but it is certain that it is related to the change of

piston areas.

Part 2: Injection Molding Actuation System

The circuit diagram of inject molding actuation system.

Manipulated variables:

1. Barrel Piston Position (From 0.001 m2 to 0.5m2)

2. Relative amount of trapped air (From 0.005 to 0.1)

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 3. Fluid density (From 960 kg/m3 to 400kg/m3)

4. Hydraulic constant pressure source (From 50 bar to 100 bar)

Default system Altered System

Cylinder pressure and Barrel Piston Position Cylinder Pressure and Piston Position with

with Barrel Piston Area of 0.001m2 Barrel Piston Area of 0.5m2

Discussion: When the barrel piston area increases from 0.001m2 to 0.5m2, it is observed that

the barrel piston cylinder pressure is visually zero from the graph. This is because according to

Pascal’s Principle, P = F/A, the greater the surface area, the smaller the pressure exerted on the

surfaces with the force remained constant as the rack mass in the system is constant. With the

surface area increased drastically, the pressure has dropped drastically as well, as

demonstrated by the theory. Also it is observed that the barrel piston position is declining all

the way to the bottom and did not managed to rise back up, due to the sub-zero fluid pressure

in cylinder barrel piston. It is unable to generate sufficient pressure, and force to push the

piston back up.

Cylinder pressure and Barrel Piston Position Cylinder pressure and Barrel Piston Position

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with Molten Plastic Relative amount of with Molten Plastic Relative amount of

trapped air = 0.005 trapped air = 0.1

Discussion: With molten plastic relative amount of trapped air increases from 0.005 to 0.1,

there should not by much difference in cylinder piston pressure but in barrel piston position,

because the molten plastic is not used as the hydraulic fluid in a system but instead it is forced

out of the nozzle and form objects to be manufactured in a mold. Thus, it is noticeable at barrel

piston position graph that the altered system with more trapped air is having higher piston

position at the end of the process, as the trapped air pressure pushes the barrel piston slightly

back into the idle position as compared to the original system.

Cylinder pressure and Barrel Piston Position Cylinder pressure and Barrel Piston Position

with molten plastic fluid density of 960 kg/m3 with molten plastic fluid density of 400 kg/m3

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Discussion: With the molten plastic fluid density reduced for more than half of its original

value, it does not affect the cylinder pressure a lot, which just faster dropping of cylinder

pressure around 7.8th second in the plot instead of dropping with the injection cylinder A’s

decline of the pressure. This is suspected to be affected by the low density of the fluid as lower

fluid density meaning lower pressure and forces are needed to push the fluid out of the

cylinder and thus it drops faster. However, it is noticed that the barrel piston location of the

last part of the graph is reverted to the original location (0m) instead of suspending in around

0.025m. This is because the low-density molten plastic fluid poses lower pressure and weight,

as well as resistance towards the barrel piston and allowing it to climb back to its original

position at 0m.

Cylinder pressure and Barrel Piston Position Cylinder pressure and Barrel Piston Position

with hydraulic constant pressure source of 50 with hydraulic constant pressure source of

bar. 100 bar.

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Discussion: With the increased hydraulic constant pressure source, it can be noticed that all of

the cylinders (Injection A and B, and barrel cylinder) are now having much higher pressure.

This is because hydraulic constant pressure source is to maintain a constant, stable pressure

supply within the system to make sure the hydraulic flow is undisrupted and works normally,

and increasing the hydraulic pressure would result in a faster fluid flow rate, which will then

cause the surge in cylinder pressure as they enter the cylinders. It is also noticeable for the

barrel piston to have much steeper slopes on its graph due to the high pressure as the fluid

flows into the barrel piston, pushing it much harder.

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Conclusion

By the end of this experiment, the students have been able to simulate two advanced fluid power

and drives systems that are widely used in automations and industrial production on MATLAB,

namely the power-assisted steering mechanism and the injection molding actuation system. Both

is used in different engineering occasions where the first system is used in most of the motorized

vehicles on the road, providing greater driving experience to all of the drivers by reducing the

effort needed to drive and steer on roads, especially for heavy vehicles that requires a lot more

forces and torque to actually turn and steer the wheels, whereas the latter system plays a huge

part in industrial production and producing plastic products that are important for the world in an

unprecedented efficiency and rate. The students are now having more understanding on the

mechanisms of the different valves and fluid circuit connections, able to suggest the application

of the system and making alteration to the system to meet the engineering application required.

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Reference

1. Esposito, A. (2008). Fluid Power with Applications. (7th Edition). Pearson.

2. Durfee, W., Sun, Zongxuan., Van de Ven, J. (2015). Fluid Power System Dynamics.

(Revised Edition). Center for Compact and Efficient Fluid Power, University of

Minnesota.

3. Daines, JR. (2012). Fluid Power: Hydraulics and Pneumatics. (2nd Edition). Goodheart-

Willcox.

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