Fuzzy PD-Based Control for Excavator Boom Stabilization Using Work Port Pressure Feedback Joseph T. Jose, Gyan Wrat, Santosh Kr. Mishra, Prabhat Ranjan, Jayanta Das Actuators, 2025 Hydraulic excavators operate in harsh environments where direct measurement of actuator chamber pressures and boom displacement is often unreliable or infeasible. This study presents a novel control strategy that estimates actuator chamber pressures from work port pressures using differential equations, eliminating the need for direct pressure or position sensors. A fuzzy logic-based proportional–derivative (PD) controller is developed to mitigate boom oscillations, particularly under high-inertia load conditions and variable operator inputs. The controller dynamically adjusts gains through fuzzy logic-based gain scheduling, enhancing adaptability across a wide range of operating conditions. The proposed method addresses the limitations of classical PID controllers, which struggle with the nonlinearities, parameter uncertainties, and instability introduced by counterbalance valves and pressure-compensated proportional valves. Experimental data is used to design fuzzy rules and membership functions, ensuring robust performance. Simulation and full-scale experimental validation demonstrate that the fuzzy PD controller significantly reduces pressure overshoot (by 23% during extension and 32% during retraction) and decreases settling time (by 31.23% and 28%, respectively) compared to conventional systems. Frequency-domain stability analysis confirms exponential stability and improved damping characteristics. The proposed control scheme enhances system reliability and safety, making it ideal for excavators operating in remote or rugged terrains where conventional sensor-based systems may fail. This approach is generalizable and does not require modifications to the existing hydraulic circuit, offering a practical and scalable solution for modern hydraulic machinery.
Neural network-enhanced internal leakage analysis for efficient fault detection in heavy machinery hydraulic actuator cylinders Gyan Wrat, Prabhat Ranjan, Santosh Kr. Mishra, Joseph T Jose, J Das Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical Engineering Science, 2025 This work presents a method for detecting internal leakage faults in hydraulic actuator cylinders using signal analysis and a supervised artificial neural network classifier. An artificial leakage is introduced into the hydraulic cylinder actuator, and a signal-based fault detection method is employed to process and transform the signals for internal leakage detection. The analysis focuses on extracting features from the pressure signal, particularly the peaks, which include information such as location, height, and width. After the neural network has undergone the training process, it is deployed for the purpose of categorizing fault levels into three distinct categories: “a healthy system,”“a system with a low fault,” and “a system with a high fault.” The proposed technique utilizes pressure difference signals from the cylinder chambers and extracts features from the peak signals to reduce dimensionality. The extracted features are then used for supervised training of an artificial neural network using a feed-forward algorithm. The trained network is capable of predicting the leakage class of unknown datasets. This method offers advantages such as reduced computational cost through feature extraction and dimensionality reduction, and it is capable of detecting multiple leakage classes. This study introduces a notably efficient approach, predicated on artificial neural networks, for the identification of internal leakage faults in hydraulic cylinders, with specific emphasis on faults arising from component wear and seal damage. The practical value of this research lies in its potential to significantly improve the reliability and efficiency of hydraulic systems used in heavy machinery. By utilizing neural networks for internal leakage detection, this research addresses a critical issue that can lead to costly downtime and maintenance in industrial operations.
Numerical Investigation on Aerodynamic Performance of Helical Savonius Rotor Inspired by Natural Shapes Pramodkumar M. Bagade, Preeti P. Bagade, Ashish Chaudhari, Prabhat Ranjan, Samartha Shirke, Chetankumar Sedani Journal of Mines Metals and Fuels, 2023 There have been extensive studies conducted on Horizontal Axis Wind Turbines (HAWT) at relatively moderate to high wind speed regions. However, such detailed investigations for Vertical Axis Wind Turbines (VAWT), specifically for low wind speed terrains are amply reported. This motivates us to conduct research to explore possibilities in improving performance of VAWT in low wind speed terrains, which is attempted in the present work. This is required due to the fact that most of regions do not have sufficient extractable wind energy due to low speeds. VAWTs can perform at such low wind speed, but are less efficient. Improving efficiency of VAWT will solve the purpose. Hence, the present study is aimed at finding the performance characteristics of VAWT for low Wind speed configurations. Various parameters affecting power generation are investigated. Numerical analyses on various configurations are conducted to study the effects of twist angle, free stream velocity, number of blades. Computational results obtained have been in good agreement with the established results for semi-circular Savonius rotor profile. The results suggest that for low wind speed terrains, there is a need to explore the combination of lift and drag type of profiles, which could be used for the utilization of available wind power. Hence, naturally inspired shapes (profiles) were investigated for the possible solution of combined lift and drag type wind turbines at low speeds. The blade shape for such combined lift and drag type wind turbine were deduced from the available literature. It is well established that the naturally inspired shapes as noted in sea conch follow golden ratio in its contours. The present study provides an insight on the characteristic curves of VAWT for low wind speed terrains, effects of various geometric and flow parameters suitable for low wind speed terrains.
Performance, Emission, and Spectroscopic Analysis of Diesel Engine Fuelled with Ternary Biofuel Blends S M Mozammil Hasnain, Rajeshwari Chatterjee, Prabhat Ranjan, Gaurav Kumar, Shubham Sharma, Abhinav Kumar, Bashir Salah, Syed Sajid Ullah Sustainability Switzerland, 2023 The demand for sustainable alternative-fuels in the transportation and agriculture domains is essential due to the quick depletion of petroleum supplies and the growing environmental challenges. The ternary-blends (diesel, biodiesel, and Methyl oleate) have the ability to report the existing challenges in this area because they offer significant promise for reducing exhaust emissions and improving engine performance. In the current work, soy methyl ester is blended with methyl oleate and diesel. The emissions and performance of blended biodiesel was conducted in common rail direct injection engine (CRDI). The characterization and physical properties were also evaluated by utilizing various methods like Fourier-Transform Infrared Spectroscopy (FTIR), UV-vis Spectroscopy (UV-vis), and Nuclear Magnetic Resonance. FTIR spectra showed the existence of the strong C=O, indicating the presence of FAME at 1745 cm−1. Again, UV-vis has reported the appearance of conjugated dienes in the oxidized biodiesel. The results indicated all blended samples retained the properties of diesel. The addition of methyl oleate improved brake specific fuel consumption of blended biodiesel almost near to diesel. D50::S80:M20 produced a mean reduction in hydrocarbon 42.64% compared to diesel. The average carbon monoxide emission reduction for D50::S80:M20 was 49.36% as against diesel.
Performance enhancement of hybrid hydraulic excavator using multiple hydro-pneumatic accumulators Prabhat Ranjan, Mohit Bhola, Gyan Wrat, Santosh Kr. Mishra, Jayanta Das Proceedings of the Institution of Mechanical Engineers Part I Journal of Systems and Control Engineering, 2020 In this article, the heavy earth moving machinery like hydraulic excavator used in the construction and mining industries has been taken into consideration. Most of the heavy earth moving machineries used in these industries are mobile with engine as the main source of power. The work deals with two different hydraulic circuits: first the proposed one and second the conventional one, and both are studied at laboratory scale, which resembles the circuit of the hydraulic excavator. In the hydraulic circuit, out of the three hydraulic linear actuators, two are connected with hydro-pneumatic accumulators and one hydro-motor is also taken into consideration, which resembles the boom, arm, bucket and swing motor, respectively. The idea behind the proposed circuit is to store substantial potential energy during downward movement of the two linear actuators in the accumulators, which resembles the boom and arm cylinder of the excavator. The stored energy is used for upward motion of the two actuators without utilizing any energy from the main pump. For the devised strategy, MATLAB/Simulink environment has been utilized for developing the simulation model and the same has been validated with the experimental data with reasonable accuracy. The effect of accumulator volume and pre-charge pressure has been studied for optimization of the accumulator size on the validated simulation model. This concept helps in saving 14.06% energy than its conventional counterpart which does not have the energy storage elements. The linear position control of the boom and the arm actuator in the proposed circuit have been accomplished using proportional–integral–derivative control and pressure-compensated proportional flow control valve and have been achieved with reasonably accuracy.
Position control and performance analysis of hydraulic system using two pump-controlling strategies Gyan Wrat, Prabhat Ranjan, Mohit Bhola, Santosh Kumar Mishra, J Das Proceedings of the Institution of Mechanical Engineers Part I Journal of Systems and Control Engineering, 2019 The role of hydraulic systems is quite evident especially in the case of heavy machineries employed in industries, where the utilisation of high forces amid large stiffness is the prerequisite. Nevertheless, there has been substantial effort put forward in the development of advanced control strategies which finally addressed the issue of the position control. Proportional–integral–derivative control strategy happens to be one among them, which is a versatile and widely renowned approach involved in the position control in this study. Although, it is quite frequently observed that the hydraulic actuation system possesses strong nonlinearities. In this article, two different actuator position control strategies, that is, swash plate control of main pump and speed control strategy of prime mover are compared. In swash plate control strategy, the proportional–integral–derivative controller adjusts the swash plate of main pump through servo mechanism, whereas in the speed control strategy, the proportional–integral–derivative controller adjusts the speed of the electric motor through variable-frequency drive. For this purpose, two MATLAB-Simulink models are developed and validated experimentally. It is found that swash plate control strategy has better dynamic and control performance than the speed control strategy catering same position demand of the linear actuator.
