Third International Conference on

Advances in Control and Optimization of Dynamical Systems

March 13-15, 2014. Kanpur, India

An Investigation on Modelling and Controller design of a Hydraulic press

A. Tony Thomas* R. Parameshwaran** R. Deepak Kumar***S.Mohanraja***M.Harishwaran***
*
Assistant Professor, Department of Mechatronics Engineering, Kongu Engineering College,
Erode, Tamilnadu, India. (tony@kongu.ac.in)
**
Professor & Head, Department of Mechatronics Engineering, Kongu Engineering College,
Erode, Tamilnadu, India. (paramesh_r@kongu.ac.in)
***
UG Student, Department of Mechatronics Engineering, Kongu Engineering College,
Erode, Tamilnadu, India. (depakroshanblu@gmail.com)

______________________________________________________________________________________________________

Abstract: Hydraulic press is a machine using a hydraulic cylinder to generate a compressive force to perform various pressing
operations like metal forging, punching, stamping, etc. When the cylinder’s extension force is controlled, the machine can be
employed for pressing operations on different materials with ease. The control problem is posed to achieve flexibility in the
machine. Mathematical model describes the behaviour of the system in terms of mathematical equations and logical models.
The steps for modelling of hydraulic press using system identification technique in MATLAB are discussed in this paper.
Using this model, three controllers’ viz., PID controller, Internal model controller and Fractional order controller are developed
and their responses are compared. The result showed that Fractional order controller gives better response than the other two
with faster settling time and smaller peak overshoot, thus helps in designing a more appropriate controller for controlling the
cylinder’s extension force.
Keywords: Mechanical engineering, hydraulic press, flexibility, system modelling and identification, robust control, Fractional
order controller, response
______________________________________________________________________________________________________

1. INTRODUCTION performed to control the pump speed which drives the

whole system.
Hydraulic press is one of the most competent forms of
press. The basic principle of hydraulic press is Pascal’s
theory which states that a constant pressure remains
throughout the system, when pressure is applied on In this paper a controller is designed to provide system
confined fluids in an enclosed system. Hydraulic press is flexibility and in addition, a comparative study is carried
built with one or more hydraulic pumps and hydraulic out with other conventional controller in order to identify
cylinders. Number of jobs is performed by hydraulic press the most appropriate controller for the system
using simply configured job parameters. It has an
advantage over mechanical press, by delivering full
pressing force anywhere within the range of stroke. Other
advantages also comprise tonnage adjustment and cycle
time maximization. Due to its simple structure and several
advantages, it has become more popular among industrial
applications. Some applications of hydraulic presses
includes Compression Moulding, Injection Moulding,
Drawing, Flying, Forging, Blanking, Coining, Clamping,
Compacting, Forming, Pad Forming, Spotting, Punching,
Stacking Stamping and Trimming.

The design of the hydraulic kit taken for study is

shown in the Fig.1. The components used in the
construction of the kit are listed in the Table.1. Some
hydraulic presses lose flexibility to operate under different
load conditions. Thereby, it causes difficulties in varying
pressing force, hence are material limited. To overcome
this problem a necessary control action need to be Fig.1 Circuit diagram of hydraulic press

978-3-902823-60-1 © 2014 IFAC 719 10.3182/20140313-3-IN-3024.00146

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S. No Description
1 Tank 50 liters
2 Filler breather FSB-25
3 Suction strainer 3/4”
4 Vane pump PVR1T-8-FRA-2080
5 Electric motor 3 hp × 1440rpm;
50Hz Foot mounting
6 In-line check valve CIT-03-5-2080
7 Pressure line filter
8 Pressure relief valve
9 Directional control valve
10 Hydraulic cylinder
Table 1 List of the components
2. LITERATURE REVIEW
Lai et al (2012) conducted the research process for
controller identification, design, modelling and control for
hydraulic system. His research concluded that,
identification system provides a convenient method to
control a nonlinear system by using linear controllers. PID
controller is designed to the system with the reference of
Ziegler Nichols tuning method. On real time control,
output response is almost similar to the reference input for
the system positioning control. Ishak et al (2012) had
implemented Nelder-Mead optimization to tune the PID
parameters for a given constraints of desired step response.
A self-tuning fuzzy PID controller was successfully
developed and applied to the electro-hydraulic actuator
using the parameters that have been optimized earlier by
Nelder-Mead algorithm. The results show that self-tuning
fuzzy PID controller seems feasible to control the electro-
hydraulic according to desired reference signal. The
proposed controller offers promising capabilities to
guarantee the robustness and position tracking accuracy of
the system. The position tracking performance was
improved by using controller parameters value of KP, Ki
and Kd for second-order model. Ljung et al (2003)
described the new developments in Math work’s System
Identification Toolbox to be run with Mat lab. Liu et al
(1998) designed a new PID controller design scheme
which uses optimisation in the frequency domain is
proposed for industrial process control. The optimal-tuning
mechanism uses the process frequency response to find
optimal parameters for the PID controller so that the
desired system specifications are satisfied.
Qin et al (1996) designed a feed forward-plus-
proportional-integral-derivative (FPID) controller for
accurate and smooth velocity control on a hydraulic linear
actuator. Results demonstrate that the FPID controller is
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capable of improving the accuracy and dynamic
performance of velocity control of a hydraulic linear
actuator. Experimental results indicate that the RMS error
from the FPID controller is about 15% and 45% lower than
that from a well-tuned feed forward controller and a well-
tuned PID controller, respectively, under ramp input
conditions. It verify that FPID control is capable of
improving the dynamic performance and the stability of
hydraulic linear actuator systems. Wen et al (2003)
developed a modified IMC structure for unstable processes
with time delays. The structure extends the standard IMC
structure for stable processes to unstable processes and
controllers do not have to be converted to conventional
ones for implementation. An advantage of the structure is
that set point tracking and disturbance rejection can be
designed separately. Rinku et al (2012) studies the control
aspect of fractional order controller in speed control of DC
motor. A comparative study of classical PID controller and
fractional order PID controller has been performed.
Concluded that the use of fractional order PID controller to
control the speed of armature controlled DC motor and
showed the variations in unit step response if the
derivative and integer order of the fractional PID controller
is varied. To obtain the optimal values of integer order and
derivative order, different optimization techniques can be
implemented. Saeed et al (2003) developed optimal
technique for tuning PID parameters for a FOPTD system
was proposed. Dimensional analysis and numerical
optimisation methods were used to simplify the procedure
of obtaining optimal relations. It was shown that the
proposed formulas have a clear advantage to Ziegler-
Nichols and Cohen-Coon methods - the most popular
techniques in tuning PID controllers. Saranya et al (2012)
focused on Internal Model Control (IMC) tuned PID
controller method for the DC motor for robust operation.
This method of control which is based on the accurate
model of the process, leads to the design of a control
system that is stable and robust. The results of the IMC
tuning method when compared with the Ziegler Nichols
(ZN) closed loop tuning provides a commendable
improvement in the overshoot, rise time and settling time
of the system.
3. MODELLING
Models describe relationships between measured signals.
It is convenient to distinguish between input signals and
output signals. The outputs are then partly determined by
the inputs. In most cases, the outputs are also affected by
more signals than the measured inputs. Such ‘‘unmeasured
inputs’’ will be called disturbance signals or noise. All
these signals are functions of time, and the value of the
input at time t will be denoted by u (t). Often, in the
identification context, only discrete-time points are
considered, since the measurement equipment typically
records the signals just at discrete time instants, often
equally spread in time with a sampling interval of T time
units. The modelling problem is then to describe how the
three signals relate to each other. The System
Identification Toolbox is for building accurate, simplified
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models of complex systems from noisy time-series data. It process.Model estimation gives the values for
provides tools for creating mathematical models of Proportional gain, Time constant and Time for our
dynamic systems based on observed input/output data. The process.
toolbox features a flexible graphical user interface that aids
in the organization of data and models. The identification
techniques provided with this toolbox are useful for
applications ranging from control system design and signal
processing to time-series analysis and vibration analysis.
State-space models are common representations of
dynamical models. They describe the same type of linear
difference relationship between the inputs and the outputs
as in the ARX model, but they are rearranged so that only
one delay is used in the expressions. To achieve this, some
extra variables, the state variables, are introduced. They
are not measured, but can be reconstructed from the
measured input-output data. This is especially useful when
there are several output signals, i.e., when y (t) is a vector.
For basic use of the toolbox it is sufficient to know that the
order of the state-space model relates to the number of
delayed inputs and outputs used in the corresponding
linear difference equation. Fig. 2 Process model window

The estimated model is given by the equation (1)

3.1 Model Development Using System Identification
Toolbox K p
y 
For the analysis of the hydraulic pressing machine, the  p S 1
process model of the system has to be developed. For the
model development, a toolbox from MATLAB called 0 . 62397
y  (1)
system identification toolbox has been used. The model 36 . 507 S  1
development steps are explained below.
6) Thus by using the working data segment, the model
has been estimated. In order to verify the fit level of
1) In order to use the input-output data of the process in
the model with the actual behaviour of the system, it
the system identification toolbox, they have to be
has to be validated. This validation is done by
converted into MATLAB variables. The data are
comparing the behaviour of the system and the
saved as MS Excel (.xls) files and are imported into
simulated output of the model. This is shown in the
MATLAB. Then the input-output data are imported
Fig.3.
into the System Identification Toolbox.
2) After importing the I/O data into the toolbox, it can
be subjected to various pre-processing methods. One
such method is ‘select range’. This is used to separate
the data into two segments. One for model
development, which is called as ‘working data’, and
the other one for validating the developed model,
which is called as ‘validation data’.
3) The separated data are then loaded in the respective
blocks, viz., working data and validation data. The
separated data are identified with variable name
followed by ‘e’ for working data and follwed by ‘v’
for validation data.
4) Once the working data is loaded, it can be now used
to estimate the model. There are various types of Fig.3 Model validation window
models that can be estimated with the available data,
such as Linear Parametric model, Non linear model, The estimated model matches with the measured data of
Spectral model, Co-relation model, Process model. the system with 97.6 % fit. Hence this model can be taken
to analyse the performance of the system.
5) The model which we desire to estimate here is a
Process model as shown in Fig.2 The parameters are
selected as per the requirement of the model for our

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4. CONTROLLER DESIGN

The performance of the system is analysed with the help of

its model equation and the appropriate controller can be
designed for the process based on the following analysis.
The system model is given as,

Where,
= 0.624
= 36.507
Fig.5 Response of ZN-PID controller
4.1 PID Controller
PID control logic is widely used in the process control 4.2 IMC Controller
industry. PID controllers have traditionally been chosen by Internal Model Control (IMC) is a commonly used
control system engineers due to their flexibility and technique that provides a transparent mode for the design
reliability. The PID controller is tuned by the Ziegler- and tuning of various types of control. Using IMC-PID
Nicholas tuning rule and the controller parameters are tuning method a clear trade-off between closed-loop
calculated as follows, performance and robustness to model inaccuracies is
achieved with a single tuning parameter. The IMC
= 526.54 controller parameters for the process as calculated are,
= 1581.20 = 32.5

= 26.33
These values are used to find the response of the system
for the given step input. The simulink model of the system
with PID controller is shown in the Fig.4
= 3.12
= 8.95
These values are used to see the response of the system
with the same Simulink model as used for the ZN tuned
PID controller (as shown in the Fig.6).
The response of the system is as follows,

Fig.4 Simulink model of the system with PID controller

The controller is set to control the system by bringing it to
the desired set point, which is 25 kN. The controller is
given with the step input. The output response of the
system for the given set point is shown in the Fig.5 Fig.6 Response of IMC controller

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4.3 Fractional Order Controller For Differentiator section,

Unlike other conventional controllers, Fractional Order =0.5, y=1, =0.0275. From the above values, the
controller does not have any tuning rules for finding the
following are calculated.
response of the system. The Fractional design procedure is
developed in a constructive manner. For the Fractional a=1.584
Order Controller Kp, Ti and Td values are obtained from
b=1.584
Ziegler-Nichols tuning rules. The λ and μ value obtained
by Minimization of Integral Square Error. The Bandwidth P0=0.346
value is obtained by marking a bode plot. The Number of
Z0=0.548
iteration value N is obtained from the respective equation
as obtained below. Using these values, N is calculated as 8.
The Bode plot is used to derive the Bandwidth of the
For Integrator section
system is shown in the Fig.7
=0.0275, µ=0.9, y= 1

From the above values, the following are calculated.

a=10
b=1.29
P0=0.312
Z0=0.0312
Using these values, N is calculated as 4. The larger value
of N (N=8) is taken for the analysis. The other parameters
as calculated are,
= 526.54

= 1581.20
Fig.7 Bode plot of the system
= 26.33
The results obtained from the Bode plot are,
λ = 0.5
 Phase crossover frequency of the system is
0.0275 rad/sec μ = 0.9
 Gain crossover frequency of the system is 15.7 The Simulink model of the system with Fractional Order
rad/sec PID is given in the Fig.8
The bandwidth of the transfer function is as follows,
Bandwidth = [0.1ω u, 10ω u]
= [1.57, 157]
The Fig.7 represents the Bode plot for the system. By
using this Bode plot, the phase and gain crossover
frequency of the system is obtained and using the result the
Bandwidth is calculated.
The equation to find the Number of Iteration is given in
the equation (2)

  W max 
 log   

  P0 
N  1  Integer
 
(2)
log  ab 
 
 
Fig.8 Simulink model of the system with fractional order
  PID

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The response of the system after the implementation of Table.2 Performance measures
Fractional Order Controller is as given in the Fig.9
Performance Measures
Tuning
methods Over Settling Integral Integral Integral
shoot Time Absolute Square Time
(%) (sec) error error error
Ziegler
Nicholas – 55.56 10.1 37.39 763.18 34.64
PID
Generalized
6.76 20.6 85.15 1114.09 501.61
IMC-PID
Fractional
order 20.48 6.8 29.95 695.95 20.14
controller
Fig.9 Response of the system with fractional order PID
controller
The above figure shows the response of the system with From the analysis and simulation of the system model with
minimal oscillations, faster settling. All these performance different controllers, it was found that the evolution of new
measures are noted for further study. controllers is laying path for a better future in terms of
technology. In such a way, the Fractional Order PID
Controller has given a better response for controlling the
5. RESULTS AND DISCUSSION force of a hydraulic pressing machine with faster settling
time (6.8 seconds) and lesser peak overshoot (20.48%) in
5.1 Comparative Study comparison with ZN tuned PID controller and Internal
Model Controller.
The responses of the system for different controllers are
taken. From these responses, the performance measures 6. CONCLUSION
are taken for comparative study to find the appropriate
controller for the system. The responses are given in the A typical hydraulic pressing machine has been taken under
Fig.10 study for analysing the performance of different
controllers on the system. Initially the mathematical model
of the system is found using the System Identification
Toolbox in MATLAB. This model equation is used to find
the response of the system with a PID controller tuned by
Ziegler-Nichols tuning rule. This found to have
unfavourable oscillations while rising and settling time of
10.1 seconds and peak overshoot of 55.56%. Then an
Internal Model Controller is used to find the behaviour of
the system. This found to have larger settling time of 20.6
seconds and peak overshoot of 6.76%. Then the response
of the system with Fractional Order Controller is studied.
It is found to have a comparatively smaller settling time of
6.8 seconds and smaller peak overshoot of 20.48%. Hence
it is concluded that the hydraulic pressing machine
controlled by a Fractional Order Controller will produce
force as per the requirements at the output. With smaller
settling time the Fractional Order Controller helps the
machine to reach the required force faster and thus it
Fig.10 Different responses of the system makes the machine flexible enough to meet the variations
at the load and also it can be employed to perform various
The performance measures are taken from the above graph pressing operations on different materials. As the system’s
and are listed below in the Table.2 real time behaviour will always be different from the
theoretical study as well as from the analysis, the hydraulic
pressing machine has to be implemented with a control
system and operated with these analysed controller
parameters. Studying the real time behaviour of the

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system, further modifications can be applied in the
controller tuning parameters which in turn the system
should provide better stabilization.
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