Hydraulic Component Characteristic Maps from Reduced Test Data
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Solution Overview
Problem
Existing methods for generating individual hydraulic component characteristic maps are time-consuming and costly, particularly due to the need for complete measurement of each individual hydraulic component to account for production-related structural deviations.
Innovation Solution
A method for automated generation of individual hydraulic component characteristic maps using a trained autoencoder, which learns to generate maps based on a training data set that includes both virtual simulation models and real measurements, allowing for the creation of a reduced individual data set during final production testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complete measurement of each individual hydraulic component is performed to account for production-related structural deviations, then manufacturing precision is improved, but loss of time and productivity deteriorate
Solution Approach 1:
A generic characteristic map is created in advance through virtual simulations that incorporate production-related structural deviations. This preliminary model captures the essential behavior patterns of hydraulic components before actual production, allowing individual components to be quickly characterized by comparing their measured data against the pre-established generic map rather than requiring complete measurements.
Solution Approach 2:
The invention uses a generic characteristic map as a template or copy that represents the typical behavior of hydraulic components. Instead of creating complete characteristic maps for each individual component through time-consuming measurements, the system creates simplified individual characteristic maps by adapting the generic map using minimal measured data from each component, significantly reducing measurement time while maintaining accuracy.
2Manufacturing precision
If complete measurement of each individual hydraulic component is performed, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The invention extracts only the essential measured data from individual hydraulic components that are necessary to adapt the generic characteristic map. Instead of performing complete measurements of all component parameters, the system identifies and measures only the critical parameters that significantly influence component behavior, thereby simplifying the measurement system while maintaining manufacturing precision.
Solution Approach 2:
The system changes the measurement approach from complete parameter measurement to selective parameter measurement. By identifying which parameters have the greatest impact on characteristic map accuracy and measuring only those parameters, the invention reduces device complexity and cost while maintaining the necessary manufacturing precision through intelligent parameter selection and adaptation of the generic map.
3Productivity
If virtual simulation models are used to generate training data, then productivity is improved, but measurement precision may deteriorate
Solution Approach 1:
The invention merges virtual simulation data with real measurement data to create a hybrid training data set. Virtual simulations provide comprehensive coverage of parameter spaces and generate large volumes of training data quickly, while real measurements from actual hydraulic components provide ground truth validation. The combination leverages the speed and completeness of simulations with the accuracy and realism of physical measurements, resolving the contradiction between productivity and precision.
Data Source
AI summary
A method for automatically generating an individual hydraulic component characteristic map for an individual hydraulic component V1, V2 of a hydraulic component type uses an autoencoder, which is trained using a training data set for the hydraulic component type, and a reduced individual data set, which is generated for the individual hydraulic component V1, V2, in order to automatically generate the individual hydraulic component characteristic map, for example in the form of a lookup table.