Rapid Thermal Energy Modeling and Analysis of Complex Industrial Hydraulic Systems

Authors

  • Ahmad Al-Issa Chair of Fluid-Mechatronic Systems, TU Dresden, Dresden, Germany https://orcid.org/0000-0003-1695-1516
  • Tobias Schulze Chair of Fluid-Mechatronic Systems, TU Dresden, Dresden, Germany
  • Jürgen Weber Chair of Fluid-Mechatronic Systems, TU Dresden, Dresden, Germany

DOI:

https://doi.org/10.13052/ijfp1439-9776.2614

Keywords:

Industrial hydraulic system, thermal energy model, Reduction of modeling time, Thermodynamics

Abstract

Modeling and analyzing the thermal energy behavior of industrial hydraulic systems with useful hydraulic power of 20 kW or higher is a challenging task due to the system’s inherent complexity and the multitude of interacting components. Conventional thermal modeling approaches rely heavily on numerous interdependent parameters and sensor measurements, including temperature, pressure, and flow rate for each port in hydraulic component. This reliance often leads to prolonged modeling times, which can exceed the actual operational time of the hydraulic system by a factor of 2 to 6.5, resulting in costly and time-intensive analysis. To address these limitations and meet industrial demands, this study introduces an enhanced thermal model based on a new temperature parameter, termed the average transient temperature (Tavg), aimed at significantly reducing the modeling time to be shorter than the experimental operation time. Furthermore, Physics informed neural network model is used to determine hydraulic oil specifications during the modeling implementation as one correlation model.

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Author Biographies

Ahmad Al-Issa, Chair of Fluid-Mechatronic Systems, TU Dresden, Dresden, Germany

Ahmad Al-Issa received the B.Sc. and M.Sc. degrees in mechanical engineering from AL-Mustansiriya University, Baghdad, Iraq in 2009 and 2012, respectively. This was followed by approximately 2 years as a university lecturer and then a 6-year industrial phase as a hydraulic engineer at General Company for Grain Processing, Ministry of Trade, Baghdad, Iraq. Currently, he is a research assistant and pursuing his PhD degree at Chair of Fluid-Mechatronic Systems, TU Dresden, Germany. His research focuses on thermal analysis and energy condition monitoring of complex industrial hydraulic systems. He is set to submit his PhD thesis on this topic later this year.

Tobias Schulze, Chair of Fluid-Mechatronic Systems, TU Dresden, Dresden, Germany

Tobias Schulze is working as a research associate and pursuing his Ph.D. at the Chair of Fluid-Mechatronic Systems (Fluidtronics) at TU Dresden, Germany. He serves as the team leader for the Fluid-Mechatronic Systems Group, with his research focusing on stationary hydraulic systems, specifically hydraulic deep drawing presses and electrohydraulic compact drives.

Jürgen Weber, Chair of Fluid-Mechatronic Systems, TU Dresden, Dresden, Germany

Jürgen Weber has been appointed in 1st March 2010 as a University Professor and the Chair of Fluid-Mechatronic Systems as well as the Director of the Institute of Fluid Power at TU Dresden, and took on the leadership of Institute of Mechatronic Engineering in 2018. He finished his doctorate in 1991 and was an active Senior Engineer at the former Chair of Hydraulics and Pneumatics until 1997. This was followed by a 13-year industrial phase. Besides his occupation as the Head of the Department Hydraulics and Design Manager for Mobile and Tracked Excavators, starting in 2002, he took on responsibility for the hydraulics in construction machinery at CNH Worldwide. From 2006 onwards, he was the Global Head of Architecture for hydraulic drive and control systems, system integration and advance development CNH construction machinery. Furthermore, Jürgen has been head of the Consulting Board for HYDAC, Sulzbach/Saar, for 10 years, still being a member, and was also appointed as a member of the Supervisory Board of Musashi Europe GmbH. He is a fellow and now chair of the Global Fluid Power Society. The membership of 5G Lab Germany at TU Dresden is a further indicator for more than 15 years of experience in management and coordination of research alliances as well as the activities as surveyor, PhD supervisor, over 300 publications, technical books and lecture notes.

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Published

2025-04-06

How to Cite

Al-Issa, A. ., Schulze, T. ., & Weber, J. . (2025). Rapid Thermal Energy Modeling and Analysis of Complex Industrial Hydraulic Systems. International Journal of Fluid Power, 26(01), 65–98. https://doi.org/10.13052/ijfp1439-9776.2614

Issue

2025: Vol 26 Iss 1

Section

Original Article

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