Electro-hydraulic Proportional Valve Research Articles

Rapid diagnosis of proportional valve pilot stage stiction fault via dynamic model-based temporal features

As the key flow control elements in modern mechatronic systems, electrohydraulic proportional valves determine the total system operating status. Due to effects such as mechanical wear, micro scale particles may accumulate in the oil and eventually cause stiction in the valve spool. Therefore, early prognosis of valve faults via spool displacement sensing is critical for efficient and economical operations. However, the spool stiction is difficult to measure due to the fully enclosed design of valves, excluding the possible sensor installation options. Traditionally, the sensor-less fault diagnosis is done by machine learning to classify the features extracted using frequency domain methods, which can be time consuming and the trained model is computationally too heavy for the onboard controller. In this paper, a light-weight spool stiction diagnosis method is proposed, where time-series features extracted from coil current signals as well as spool dynamics can be used to quantitively determine the stiction severeness. A hardware-in-the-loop test bed is designed to perform valve spool stiction simulating experiments, and a piloted operated solenoid proportional valve is selected as the validation target. A three-layer regression neural network is established as the baseline. Initial results show the proposed model can detect spool stiction at various degrees, which accuracies are on par with the baseline neural network but nearly three orders of magnitude faster.

Simulation analysis and optimization of pilot type electro-hydraulic proportional directional valve based on multi field coupling

The pilot-operated electro-hydraulic proportional directional valve is widely used in complex and precision engineering fields. Its operational stability and reliability determine the overall performance of the hydraulic system. During the working process of the pilot-operated electro-hydraulic proportional directional valve, the spool is deformed due to the influence of pressure and temperature, resulting in problems such as clamping or stagnation. In order to solve this problem, this study uses the fluid-solid-thermal coupling simulation method to analyze the flow field characteristics and thermal deformation of the spool with different structural throttling grooves, and optimizes the U-shaped throttling groove structure. The results indicate that as the valve opening increases, the front section of the throttling groove becomes the primary region where the maximum radial deformation of the spool occurs. In this paper, the steady-state flow force of the valve core is taken as the measurement standard, the constraint range of the structural parameters is determined, and the radial thermal deformation is included in the optimization analysis of the structural size. It’s verified that the optimized flow characteristics are improved by about 32 % compared with that before optimization, and the maximum steady-state flow force after considering thermal deformation is reduced by about 4N compared with that before optimization. This provides an important design basis and reference for the structural design and optimization of the pilot electro-hydraulic proportional directional valve.

Comparison of Advanced Multivariable Control Techniques for Axial-Piston Pump

This article is devoted to a comparison of two advanced control techniques applied to the same plant. The plant is a certain type of axial-piston pump. A linear-quadratic (LQR) controller and an H-infinity (H∞) controller were synthesized to regulate the displacement volume of the pump. The classical solution to such a problem is to use a hydro-mechanical controller (by pressure, flow rate, or power) but, in the available sources, there are solutions that implement proportional-integral-derivative (PID), LQR, model predictive control (MPC), etc. Unlike a classical solution, in our case, the hydro-mechanical controller is replaced by an electro-hydraulic proportional valve, which receives a reference signal from an industrial microcontroller. It is used as the actuator of the pump swash plate. The pump swash plate swivel angle determines the displacement volume, respectively, and the flow rate of the pump. The microcontroller is capable of embedding various control algorithms with different structures and complexities. The developed LQR and H∞ controllers are compared in the simulation and real experiment conditions. For this purpose, the authors have developed a laboratory experimental test bench, enabling a real-time function of the control system via USB/CAN communication. Both controllers are compared under different pump loading modes. Also, this paper contributes an uncertain model of an axial-piston pump with proportional valve control that is obtained from experimental data. Based on this model, the robust stability of the closed-loop system is investigated by comparing the structure of a singular value (μ). The investigations show that both control systems achieved robust stability. Moreover, they can tolerate up to four times larger uncertainties than modeled ones. The system with the H∞ controller attenuates approximately at least 30 times the disturbances with frequency up to 1 rad/s while the system with the LQR controller attenuates at least 10 times the same disturbances.

Modelling and characteristics analysis of an electro-hydraulic proportional valve with a discrete pilot stage for underwater hydraulic manipulators

As the harshness of the underwater operating environment and complexity of underwater tasks gradually increase, underwater hydraulic manipulators with high reliability and precision attract more research attention. To improve the reliability and dynamic performance of the traditional electro-hydraulic proportional valve (EHPV) used in the underwater hydraulic manipulator, an improved electro-hydraulic proportional valve with a discrete pilot stage (DEHPV) is proposed. In the pilot stage, two 2-position 3-way normally open high speed switching valves (HSVs) are used, and the initial oil spring stiffness in the control chamber is large enough to maintain the dynamic performance of the DEHPV. First, the working principle and configuration of the DEHPV are both given, and the coupled electric-magnetic-mechanical-fluid model of the DEHPV is presented. Moreover, a dual-valve hybrid pulse width modulation (DVHPWM) control strategy is proposed to improve the position tracking accuracy of the DEHPV. Furthermore, a co-simulation model of the DEHPV considering the multi-field coupling law is established to study the dynamic characteristics. Extensive experiments are carried out to verify the effectiveness of the proposed structure as well as its good dynamic performance and control accuracy.

Intelligent residual film recovery machine monitoring and control system

Domestic residue recovery machines in China still follow the traditional towed mechanical model, lacking automation and intelligent features. Under the key R&D project of Xinjiang Autonomous Region, our team has developed integrated intelligent agricultural machinery for cotton straw crushing and residue recovery. This research covers the monitoring and control system, including PLC control and communication, working parameter monitoring and adjustment, algorithmic control of electro-hydraulic actuators, and human-machine interface display. Compared to traditional models, this machine replaces the conventional chain-driven mechanical structure and diesel tractor traction power with a fully hydraulic integrated suspension drive and power system. Sensors, PLC, and a touch screen are utilized for real-time monitoring and display of parameters. Hardware components like electromagnetic switch valves, electro-hydraulic proportional valves, hydraulic cylinders, and software elements such as PLC programs and intelligent control algorithms are employed for electro-hydraulic switching and proportional control of certain working parameters and mechanisms. All parameter information is consolidated in the PLC host and expansion modules and displayed and controlled on the human-machine interface. The system was installed on the first-generation machine for indoor testing, revealing that the monitoring and control system used on the first-generation machine achieves parameter detection and adjustment of the actuating mechanisms. It incorporates more advanced functions compared to traditional residue recovery machines. However, there is still ample room for improvement in the overall intelligence of the machine. The control system’s structure requires adjustment, and certain functionalities of the overall mechanical structure and working components need optimization or upgrading. Detailed enhancements to the entire system will be made in the next-generation machine.

Recent advances in control strategies and algorithms for pilot-operated electro-hydraulic proportional directional valves

Pilot-operated electro-hydraulic proportional directional valve is a key hydraulic component to control the motion of large power equipment such as construction machinery and agricultural equipment. The control accuracy and response speed of the valve control element are very important to the performance of the hydraulic system. In this paper, control strategies for dead-zone control and valve control systems are reviewed. In order to eliminate the dead-zone of pilot-operated proportional valve control, the current control schemes for dead-zone detection and dead-zone compensation are summarized, and the control schemes are evaluated. The proportional–integral–derivative-related control, nonlinear control, and robust control of the pilot-operated electro-hydraulic proportional directional valve control system are reviewed, the relationship between the control strategies is analyzed, and the different control algorithms are evaluated. The shortcomings of the research program are analyzed, and the corresponding solutions are proposed. Based on the current research, future research progresses for eliminating the control dead-zone and optimizing control strategies are presented.

Full circumferential reluctance maglev coupling for 2D proportional flow rate valve: Design, modelling and experimental validation

A novel full circumferential reluctance maglev coupling (FCRMC) is proposed in this paper, which not only meets the requirements of force transmission and valve position feedback of two-dimensional (2D) valve but also has the advantages of closed-loop magnetic circuit and high magnetic energy utilization rate. To investigate the torque-displacement characteristic of FCRMC, a detailed analytical model based on the equivalent magnetic circuit method is formulated, which considers the leakage flux effect, edge effect, and magnetic permeability nonlinearity. The effects of the inclination angle, width, air gap, and number of teeth on the torque are explored by the analytical model, and appropriate structural parameters are selected to design and manufacture the prototype. A dedicated test bench is built and the static/dynamic characteristics of FCRMC are tested. The experimental results show that the FCRMC prototype has a step velocity of 20.8 × 10−3 mm/ms, a torque-volume ratio of 8.47 × 10−3 N m/cm3, a torque-permanent magnets(PMs) volume ratio of 0.050 N m/cm3, and a step velocity-PMs volume ratio of 2.63 × 10−3 mm/ms·cm3. Finally, to verify the feasibility of the FCRMC in real work situations, the FCRMC is applied to a 2D electro-hydraulic proportional flow valve. The experimental results show that, at 15 MPa, the no-load flow of the valve is 82.4L/min, with a hysteresis of 3.8 %, a step velocity of 17.5 × 10−3 mm/ms, and amplitude and phase frequency widths of 22.4 Hz and 26.5 Hz.

Dynamic modeling method for an electro-hydraulic proportional valve coupled mechanical–electrical-electromagnetic-fluid subsystems

On the basis of differences of the magnetoresistance, magnetic field direction and relative permeability in metal components, a magnetic cycle method with modifications also characterizing magnetic flux densities of different components in real time is firstly proposed, thus establishing mathematical models for the electromagnetic subsystem of an electro-hydraulic proportional valve. Further integrating electrical, electromagnetic, fluid dynamic and mechanical models together, analytical and fully coupled mathematical models are achieved so that nonlinear dynamic performance determined by the structural parameters, materials, fluid, driving strategies and interaction of subsystems will be captured effectively. Secondly, a coupled finite element (FE) model with all subsystems is also established, and dynamic behaviors under different driving strategies such as the high-low voltage (HL), direct current (DC) and pulse width modulation (PWM) are reflected through the moving mesh method in COMSOL Multiphysics, further suggesting the HL strategy as the better one because of small overshoot and shortest response times. Under the same driving strategy such as PWM, results of two models are highly similar to each other with the maximum time difference of 5 ms and the absolute error of steady-state position of 0.0104 mm. Therefore, two dynamic models are relatively accurate, and such an integrated method presents another reference for predicting dynamic behaviors of complex valves.

Axial-piston pump optimal multivariable PID controller tunning

The aim of the present work is the synthesis and optimal tunning of a PID controller designed to control the displacement volume of an axial-piston pump intended for hydraulic systems with open circulation. The pump is controlled in real-time through a system developed by the authors based on an electro-hydraulic proportional valve (replacing the conventional hydro-mechanical controller) and an industrial controller. The experimental system was initially used to obtain a data set that is used in a system identification procedure to obtain a model. The obtained state space model was used for the synthesis of the PID controller. The optimal tunning of controller parameters is performed using three modern methods: genetic algorithm, simulated annealing and pattern search. The resulting three PID controllers with different settings depending on the used methods are compared in simulation and experimental conditions. Based on the results, an analysis of the control performance was carried out.

Design, Modelling, and Analysis of a Capacitive Reservoir Based PWM Digital Circuit of Electro-Hydraulic Proportional Valve

The high-speed and high-accuracy current control circuit is a key component for the high-performance electro-hydraulic proportional valve. In this paper, a new capacitive reservoir-based PWM digital circuit (CRPDC) is designed, modeled, and analyzed. The proposed CRPDC employs a capacitive reservoir circuit to acquire electricity from the DC power supply while the PWM control signal is at a high level and the supply current for the proportional valve coil while the PWM control signal is at a low level, which will result in a small ripple and fast response of the coil current. For the proposed CRPDC, the charging and discharging mathematical models are specially established to reveal the response characteristics of the proportional-valve coil current. The coil current control performance of the proposed CRPDC is simulated by the mathematical models and the Multisim models. Simulation results demonstrate that the designed CRPDC can energize the coil current in a high-accuracy and fast-speed manner. In summary, the designed CRPDC has wide application in the current control of the proportional valve coil.

Evaluation of Hydraulic Characteristics of Electrohydraulic Proportional Valve (EHPV) for an Auto-Steering Tractor Application

The performance of the electrohydraulic proportional control valve (EHPV) employed in a tractor’s automatic steering system directly influences the steering performance. To develop a highly reliable EHPV, it is essential to analyze the hydraulic characteristics of the EHPV for several working conditions of tractors. This study aimed to measure and analyze the hydraulic characteristics of the EHPV according to tractor working conditions. The flow rate and pressure data of the EHPV were computed through the valve measuring system, and the required power was computed. The experimental conditions were selected based on engine rotational speed and tractor steering angle. As a result, it was discovered that the flow rate, pressure, and power all increased when the engine rotation speed and steering angle conditions increased. Furthermore, the rates of increase in flow rate, pressure, and power based on the increase in the steering angle were higher than when the engine rotation speed increased. In the regression analysis results between the two variables and the hydraulic characteristics of EHPVs, the steering angle demonstrated a higher correlation than the engine rotation speed. In conclusion, the steering angle and engine rotational speed are the major variables in the hydraulic characteristics of EHPVs, and the influence of the steering angle is greater.

An Analysis of the Static and Dynamic Behavior of the Hydraulic Compensation System of a Multichannel Valve

Electro-hydraulic proportional valve is the core control valve in many hydraulic systems used in agricultural and engineering machinery. To address the problem related to the large throttling losses and poor stability typically associated with these valves, here, the beneficial effects of a triangular groove structure on the related hydraulic response are studied. A mathematical model of the pressure compensation system based on the power-bond graph method is introduced, and the AMESim software is used to simulate its response. The results show that the triangular groove structure increases the jet angle and effectively compensates for the hydrodynamic force. The steady-state differential pressure at the valve port of the new pressure compensation structure was 0.65 MPa. Furthermore, experimental results show that the pressure difference at the main valve port is 0.73 MPa, and that the response time is less than 0.2 s. It is concluded that the new compensation structure has good pressure compensation response characteristics.

Elektro-Hidrolik Servo Valf Sisteminin Arı Algoritması (AA) Kullanılarak Modellenmesi

In this study, a method is proposed to find the unknown simulation parameters of an industrial electro-hydraulic proportional valve. Electro-hydraulic servo systems are one of the most widely used actuator systems, and proportional valves are commonly found in hydraulic systems. Hydraulic systems are complicated to linearize, because nearly whole elements are nonlinear, with the inclusion of the valve actuators. The system model must be linearized to make it feasible for analysis of the system linearly or the characteristics must be identified by comparison the output responses suitable for the inputs. However, it is not easy to obtain a perfect system model for use in simulation studies without prior knowledge of the system. Obtaining a perfect model of a system that is not easy to model can be done in two different ways; applying one of the system identification methods after collecting experimental data or using manufacturers' datasheets. In this paper, simulation parameters of MOOG brand D675 series proportional servo valve system were obtained using The Bees Algorithm, an optimization algorithm, to match the dynamic specifications in the datasheet provided by the manufacturer. The obtained system model and the answers are shown graphically and the effectiveness of the proposed method is discussed.

An Adaptive Robust Impedance Control Considering Energy-Saving of Hydraulic Excavator Boom and Stick Systems

In this article, taking the hydraulic system of mining hydraulic excavator boom and stick as the plant, an adaptive robust impedance controller based on an extended state observer and backstepping method is designed. The energy-saving operation and position tracking performance are considered in system modeling and control law design. The system effects on electro-hydraulic proportional valves with open centers and flow regeneration valves (FRVs) are considered. When hydraulic cylinders are extended, the proposed control strategy adopts a pump-controlled pressure closed-loop to shorten the dead time. When hydraulic cylinders are retracted, less oil is output to meet the idle demand. The valve-controlled position subsystem with impedance mode ensures smoother digging processes. Comparative simulations show that the proposed control strategy has better position tracking and smaller velocity fluctuations. Compared with the system without FRVs, the proposed system can reduce energy consumption by 27.32%.

A dynamic modelling method for an electro-hydraulic proportional valve combining multi-systems and moving meshes

A dynamic modelling method for an electro-hydraulic proportional valve combining multi-systems and moving meshes

Application of Electrohydraulic Proportional Valve for Steering Improvement of an Autonomous Tractor

Application of Electrohydraulic Proportional Valve for Steering Improvement of an Autonomous Tractor

Research on performance of liquid drive fan cooling system for hydrogen fuel cell forklift

Due to the large energy consumption as well as poor controllability and other problems, the traditional cooling system has not been able to adapt to the development needs of construction machinery with the continuous upgrading of emission regulations. This paper introduces a hydraulic driven fan cooling system based on pilot operated electro-hydraulic proportional valve. In order to make the whole machine quickly reach the temperature required in the best working condition when the construction machinery starts working, controlling the fan at a lower speed can reduce the heat dissipation and save energy. The electronic control system will adjust the motor speed in time when the temperature of the fluid rises, and control the temperature in the best temperature range required. A one-dimensional simulation model of this stepless speed control system is established to predict the parameter sensitivity of the electro-hydraulic proportional valve and the dynamic performance of the system. The simulation shows that the fan speed of the system can reach the required speed in only 5s at the extreme high temperature of 40 °C; the fan input power of the system accounts for 65% of the system input power at −30 °C and reaches 80% at 40 °C. Three-dimensional simulation shows that the fan-front temperature-controlled cooling system for forklift truck has high heat dissipation efficiency and can be applied to other heavy machinery products.

Study on Characteristics of 2D Cartridge Electro-hydraulic Proportional Flow Rate Valve

Study on Characteristics of 2D Cartridge Electro-hydraulic Proportional Flow Rate Valve

Modeling, simulation and experimental validation of flow rate of electro-hydraulic hitch control valve of agricultural tractor

Advances in non-linear control theory have made it possible to develop controllers for non-linear dynamic systems in their nature. The low-cost proportional control valves of the hydraulic control system are examples of such a system where there is no linearity due to the structure of the valves and the flaws in the spool. However, the non-linear analysis and regulation of these hydraulic systems cannot be done without a proper valve model. This paper presents a methodology for the development of an efficient unified model of a three-point hitch (TPH) electro-hydraulic proportional control valve control system for agricultural tractors by means of a parameter estimation technique. Modeling and simulation of the proportional control valve was performed using MATLAB Simulink software. Parameter estimation methodology was used to optimize the effective orifice opening of the solenoid valve to meet the flow characteristics available in the manufacturer's technical data sheet for the proportional control valve model parameters. Such unified Simulink models are useful for simulation, practical capability testing, and non-linear control design. Modeling and simulation of electro-hydraulic hitch (EHH) control valve were made and simulation results were compared with actual experimental results. The simulation results of the TPH lifting and lowering time were found to vary 4 and 12.5 %, respectively with the experimental results. This type of parameterized valve models facilitates their implementation in dynamic simulation models of complex hydraulic systems.

Electro-Hydraulic Proportional System Real Time Tracking Control Development Based on Pulse width Modulation Method

The presented work was directed to develop the dynamic performance of an electro-hydraulic proportional system (EHPS). A mathematical model of the EHPS is presented using electro- hydraulic proportional valve (EHPV) by Matlab-Simulink, which facilitates the simulation of the hydraulic behavior inside the main control unit. Experimental work is done and the closed loop system is designed using the linear variable displacement transducer sensor (LVDT). The controller of the system is an Arduino uno, which is considered as a processor of the system. The model is validated by the experimental system. The study also presents a real time tracking control method, based on pulse width modulation, by controlling the speed of the actuator to achieve the position tracking with minimum error and low transient time, by applying the constant input signal 50mm the transient time was 0.9 seconds and the error 1.8%.