Optimization Design and Experimental Validation of a Multi-Orifice Sleeve Buffer for Enhanced Impact Protection in High-Speed Hydraulic Actuators

As a critical component for motion control in heavy machinery, high-speed hydraulic actuators require effective buffering to mitigate end-impact. This paper proposes a compact buffering cylinder with a multi-orifice sleeve. A theoretical model was established to derive the throttling area profile for constant deceleration. A detailed numerical simulation model was then developed, and the key orifice parameters (diameter and spacing) were optimized using a Particle Swarm Optimization (PSO) algorithm to maximize buffering efficiency and smoothness. A prototype based on the optimal design was manufactured and tested dynamically. Experimental results demonstrate that the buffer smoothly arrested a piston with an initial velocity of 8 m/s and a moving mass of 80 kg within a 250 mm stroke. The optimized design achieved a 14% increase in buffering efficiency and reductions in peak force and pressure compared to the initial design, validating the proposed optimization methodology and providing a reliable solution for high-speed actuator protection.