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Training Servo Hydraulic Drive Systems 36
Training Servo Hydraulic Drive Systems 36
Training Servo Hydraulic Drive Systems 36
Required knowledge: Hydraulic drives, hydraulic circuits and basic physics of machine dynamics
Version 3.6
Why is it not possible to size a servo or proportional valve without knowing the controlled system?
The servo or proportional valve is an integral part of the controlled system and has to be adopted to the system.
controlled system
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Rated Flow
Q = QN
p p N
Note: Above equation is only valid when the flow speed is < 30m/s, above this flow speed we get flow saturation. This means, even with higher pressure drop no increase of flow will happen! Higher flow speeds lead to cavitation and increased wear of the valve.
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The listed max. flow can only be achieved, when all components in the loop are designed for the required flow!
Normally this means, that all additional components as well as pipes/drillings in the loop are one size bigger than the proportional or servo valve! At manifold blocks it is important to have suited drilling diameters (bigger than valve ports) and a low flow resistance design!
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Hydraulic Power Transmission The smallest possible valve is the best valve for closed loop control!
Hydraulic Power Transmission at a Throttle Valve
100 90
80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 100
Differential Pressure in %
At 1/3 pressure drop over the valve you get the smallest possible valve for a given application!
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m
T
> < ><
The center position of a zero lapped valve spool represents a hydraulic resistor bridge circuit.
A
> >< <
At movement only 2 resistors are active, one in meter-in the other in meter-out function.
P
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Caution: To stop a hydraulic drive with zero lapped valves in a position requires a closed loop system. The spool center position cannot be used for safety circuits.
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Q
characteristic of hydraulic resistor
i U Ux
i
characteristic of electric resistor
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Pressure Gain of a Zero Lapped Valve When flow in A and B is zero (e.g. blocked actuator) there is a flow across the 4 adjustable throttles (= valve metering edges). The slope of the plot of the differential pressure A-B over the valve command signal is the pressure gain.
T
> < ><
A
>
spool displacement
B
><
<
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xA A[dB ] = 20 log xE
The natural frequency of the valve as well as the damping of the valve can be taken from the frequency response plot.
D633
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Acceleration Force (Mass Force) Acceleration means a change of the speed of a mass. To change the speed of a mass forces are required. acceleration means a force in the direction of movement deceleration means a force against the direction of movement (acceleration, speed and force are vector variables)
Fm = m * a
[1 kg * 1 m/s = 1 N]
Example: A mass of 500 kg has to be accelerated (or decelerated) within 25 ms from 0 to 1 m/s. Linear acceleration: Acceleration force: a = v/t = 1m/s / 0,025 s = 40 m/s Fm = m * a = 500 kg * 40 m/s = 20.000 N
At an actuator area of 25 cm an acceleration pressure of 80 bar is required. Deceleration under the same conditions means deceleration pressure.
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Equation: Gravity:
Fg = m * g g = 9,81 m/s
Example: Weight (force) of a 500 kg mass Weight (force): pressure: Fg = m * g = 500 kg * 9,81 m/s = 4.905 N p = force / area
At vertical actuators and an actuator area of 25 cm, this means a load pressure of approx. 20 bar caused by the weight.
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Sizing of Proportional- or Servo Valves taking metering edges and dynamic effects into account
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+/- Fm
m
pA A >< Q1 P T B pB ><
FExt
FG = m * a + FExt Q2
Q = QN p p N
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Fm
m
pA A >< Q1 P T B pB ><
FExt
FG = - (m * a) + FExt Q2
Q = QN p p N
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Fm
m
pA A >< Q1 P T B pB >< Q2
FExt
FG = m * a + FExt
Q = QN p p N
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Question: What is the required pressure in P, to get during deceleration exactly 0 bar in port A (means, just no cavitation)? Data: deceleration pressure in port B: pB = 80 bar tank pressure pT = 0 bar symmetrical valve spool cylinder area ratio 2:1, means QPA = 2 x QBT
pressure drop B-T pBT = pB pT = 80 bar 0 bar = 80 bar pressure drop P-A pPA = pP pA as pA is 0 bar pPA = pP
p N QN = Q p
pPA
Q = PA pBT Q BT
pPA
2 QBT = Q BT
80bar
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v F
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Very critical case: Hanging (rod top down), extending differential actuator decelerates
Prerequisite for controllability pA & pB > 0 bar
v pA >< Q1 P T >< Q2 pB
FG
FG = m * a + Fg + FExt
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When the pressure in one of the actuator chambers gets < 0 bar the drive cavitates.
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Special Spools
Technically the most elegant and normally the most cost effective solution, is applying an asymmetric valve spool or using a regenerative circuit. E.g. an asymmetric 2:1 spool. The rated flow of the B-channels (QPB and QBT) is 50% of the rated flow of the A-channels (QPA and QAT). QPA and QAT = 2 * (QPB and QBT) (Note: connect always the high flow to the A-port) 2:1 is in line with a frequently used cylinder geometry. The asymmetric valve spool provides additionally to the cavitation prevention also a better chucked cylinder, what improves the drive stiffness and therefore the controllability.
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B
Caution: Ports A and B must not be exchanged
Note: The big piston area should be connected to port A of the valve!
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Regenerative Circuit (Disadvantages, less force at extending and less drive stiffness)
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Regenerative Circuit
m
A B Special spools can automatically change over to normal circuit at low signal levels. There is no generally suitable regenerative spool available. The optimization of the spool has to be done application specific
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Additional Selection Criteria for Proportional Valves Ambient temperature range (min. / max.) Shock, vibration at valve location Electric environment (EM-Fields, HF devices, required protection
class IP??, explosion proof etc.)
Fluid Filtration (For filtration sizing, use publications about this subject) Human- and machine safety regulations Special approvals for designated applications
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Mechanics
Friction Load Moved mass Stiffness Bearing backlash
Hydraulics
Flow, pressure Static and dynamic valve characteristics Actuator geometry Actuator seals Pipe/hose geometry
Electronic
Type of controller Resolution of sensors Resolution of A/D and D/A converters Controller sampling time Linearity, hysteresis, temperature drifts of Sensors & valves
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Fluid Compressibility
F = p*A
18.000 16.000
E flu id in b a r
s s
14.000
12.000
10.000
8.000
6.000 10 40 70 100 130 160 190 220 250 280 310 340 370 400
pressure in bar
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c A
m V0, Efluid
c = m
c fluid
A2 = E fluid V0
c fluid 2 E fluid A2 = H = m V0 m
Efluid = Bulk modulus of fluid A = piston area V0 = trapped volume
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/min
50
99
stroke in %
The natural frequency of the drive is, at position- and speed control systems, a measure for the dynamic limits (acceleration) and the achievable loop gain (accuracy) of the closed loop system.
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Pipe characteristics
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Pipe models
Equivalent mechanic pipe model
Q0 p0
m
(LHI, RHI)
m
(LHI, RHI)
Q1 p1
L C
Lenght of pipe in m 0,5 1 2 5 8 10
1 CL
L =
El l2
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Note:
Best stability and accuracy results can be achieved when the pressure sensor is mounted directly at the actuator. Reason is the inductivity of the oil between the valve and the actuator as well as the pressure drop in the pipe. A too fast valve will cause pressure oscillations.
Example: Pressure over time in a pipe. L = 5m, every 0,7 m a pressure test point, time scale 20ms
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Pressure Pulse (Joukowskys pulse) Due to the inductivity of the fluid in a pipe, a pressure pulse is generated at the valve ports when closing the valve. It has to be distinguished between abrupt and slow valve closing:
tcrit
2l = cFluid
l = length of pipe c = sonic speed in fluid (c = 1366 m/s steel pipe, c = 462 m/s HP-hose)
A valve closing time smaller or equal tcrit means abrupt closing, else slow valve closing. Pressure pulse at abrupt valve closing:
v = change of fluid velocity
p = c v
v l tV
p = 2
Cavitation at the tank port of the valve can emerge. (The required preload pressure to avoid cavitation can be calculated)
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250
p = c v
or
150
100
p = v El
50
0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 lgeschwindigkeit in m/s
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Pressure Pulse (Joukowskys pulse) At slow valve closing a pressure pulse crops up as well. In this case the pressure pulse depends on the pipe length! Cavitation at the tank port of the valve can emerge. (The required preload pressure to avoid cavitation can be calculated with the equation below)
v l p = 2 tV
Note: The pressure pulse when closing a valve, caused by the pipe inductivity (Joukowskys pulse), has to be added to the pressure pulse caused by the moving mass (inertia) of the drive system.
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m
To achieve a high natural frequency of the drive the valve has to be mounted close to the actuator. Apply hydraulic accumulators close to the valve in P and T, at pilot operated valves also in X and Y. The pipes between the accumulators and the valve have to be extremely short with as big as possible diameter, without any restrictions in the pipe or drillings. Apply in the T pipe an orifice and a pressure preload valve, to avoid cavitation. Pipe between orifice and preload valve as long as possible (high inductivity).
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Note
Due to its inductivity and capacity hydraulic pipes are oscillatory systems with a natural frequency, which act in a hydraulic system as a low pass filter. When sizing dynamic drive systems it is mandatory to take the pipe dynamics into account. Neglecting the dynamic pipe effects cause a high risk, that the drive system cannot achieve the required performance and damages are very likely. Mainly the frequently underestimated T-pipes cause severe problems due to cavitation. The required accumulators have to be sized by experts with a natural frequency above the valves operating frequency. A normal accumulator sizing is in most cases not sufficient! Note: The operating frequency of the pilot stage of pilot operated valves is approximately two times the main stage frequency.
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sv, Dsv w x xw Kp
Controller
H, DH Acyl
KHy
KV
KSensor
Sensor
w x xW KV
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(KV is calculated according the stability criteria and depends on the natural frequencies and damping factors) Max. velocity error
vmax s = KV
KV = loop gain H = natural frequency of the hydraulic drive DH = damping factor of the hydraulic drive SV = natural frequency of the servo valve SV = f SV 2 DSV = damping factor of the servo valve (can be calculated from the amplitude ratio) vmax = maximum speed at 100% open valve (rated flow of valve !)
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Thumb rules for component sizing at position- and speed control systems:
To achieve the max. performance of the hydraulic drive, the natural frequency of the servo valve should, at well damped systems, 3times higher than the natural frequency of the actuator. At poorly damped systems (most cases) the natural frequency of the servo valve should be slightly below the natural frequency of the actuator. Caution: The natural frequency of pilot operated valves depend on the pilot pressure. Drives with a natural frequency < 5 Hz are poorly (only with very high effort) controllable. Above 25 Hz natural frequency, hydraulic drives are normally well controllable. The trapped oil volume between valve and actuator should be as small as possible, to achieve a high natural frequency. Design the system for automatic bleeding ! The smallest possible valve for the application is the best possible valve! (Rule: As much as possible electric- as less as possible hydraulic gain in the loop) The natural frequency of the sensors should be 10times higher than the natural frequency of the drive.
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Pconst.
p A i
Controller
P T
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SV, DSV KP w x xw
Controller
VQp
CH
KV
Sensor
w x xW KV
CH =
V El
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Notes:
The application limits are defined by the stability criteria and the valve resolution (threshold). At pressure and force control loops are significant stability restrictions in case the natural frequencies of attached spring-mass-systems and of the oil in the pipe between valve and actuator are not significantly above the valves natural frequency. External spring-mass-systems can be excited to resonance ! The natural frequency of the pipe is a low pass filter between valve and cylinder, what means the valve dynamics cannot be transmitted !
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c = m
m
pconst
A
Natural frequency of the fluid in the pipe (low pass filter) ! At force- and pressure control loops, the natural frequency of an attached spring-mass-system and the natural frequency of the oil in the pipe between valve and actuator is a criteria for the dynamic limits and the possible loop gain of the control loop, in case it is not significantly above the valve natural frequency.
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Forward branch: Errors in the forward branch are divided by the controller gain
w x
xw
Controller
Sensor
Backwards branch: Errors in the backwards branch are mirrored 1:1 in the control loop results. This means, the sensor is a key component for the accuracy.
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Additionally to the limits due to the possible loop gain are at all control loops, more frequent at pressure/force control loops, limits due to the valve resolution (threshold). An electric feedback valve (EFB) has typically a resolution (threshold) of approx. 1:1000. This means the smallest adjustable spool position is 0,1% of the maximum spool position. At drives, with high speeds (> 0,5 to 1m/s), it is recommendable to use a progressive spool, to improve the flow resolution at small signals. The same applies to pressure control loops. Operating at the valve resolution limits, leads to limit cycling.
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A proportional valve has to be sized for the operating point which requires maximum valve opening. Normally this operating point is at maximum speed (max. Q) and maximum load (smallest p), in some cases at maximum acceleration. In doubt several operating points have to be calculated. A valve is optimal sized, when the maximum valve opening is 70 to 90%. To determine the operating point, mass forces, flow saturation and cavitation have to be considered. At position- and speed control loops it is in most cases sufficient to select a valve with a natural frequency close to the natural drive frequency. At pressure- and force control loops the highest possible natural frequency of the valve is in most cases beneficial.
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After sizing the servo valve according to the mentioned rules, the physical limits of the drive (closed loop controlled system) are known and a proper function will be achieved. With the calculated values the closed loop controller can be defined. The art of closed loop control is to utilize the physical possibilities of the closed loop controlled system.
A poor performing controlled system cannot be improved even with the best closed loop controller.
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Due to the complexity of sizing a servo hydraulic drive system it is recommendable to use a sizing software. Such a software makes it easy to calculate, in case needed, several operating points of a drive.
Based on the sizing results a more accurate prediction of the dynamic drive performance can be achieved with a dynamic drive simulation.
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