Hydraulic Proportional Control - Bosch Rexroth

Design & Control of Proportional and Servo Systems
Bosch Rexroth Industrial Hydraulics Rob Decker & Dave Saaski April 2008 Drive for Technology CMA/Flodyne/Hydradyne, Inc.
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History of Hydraulic Control

Mechanical No Electric
Flow Controls, Limit Switches and Relay Logic
Using Closed-loop Controllers Examples of Closed Loop Controllers Analog Lower Cost Computer not required for set-up or adjustment Examples:
VT-MACAS (AVPC-V or AVPC-mA) - Position or Velocity Control Card p/Q Cards Open Loop Flow, Closed Loop Pressure Control Card
Digital
HACD Hydraulic Axis Controller: Digital HNC Hydraulic Numerical Controller
VT-MACAS (AVPC) Analog Velocity Position Control / V or mA
Material Number for Voltage Command = 0811405139 Material Number for milliAmp Command = 0811405140
VT-MACAS (AVPC) Analog Velocity Position Control / V or mA
VT-MACAS (AVPC) Schematic
AVPC / Applications
Position Control
Velocity Control
P/Q Cards with Valve Amplifier
P/Q Cards for Valves with OBE
Front Plate
P/Q Card Applications
Controller for the Pressure Difference (Force Control)
HACD
HACD (Hydraulic Axis Controller - Digital) Multi-loop 32-bit Digital Controller DeviceNet Available CANOpen - In development PROFIBUS - In development New Generation Upgrade of the DMX
HACD Technology: European + American Product Experience
1997 to 2003 Joint Development
Bus Controllers - HACD

6 analog Inputs, Voltage or Current (selection via software) 2 analog Outputs, 1x voltage or current (selection via software) Digital Feedback SSI or Incremental 8 digital inputs (configuration via software) 7 digital outputs (configuration via software) Enable Input and OK Output Display and Keys Serial Interface RS 232 CAN Bus - DeviceNet and CANOpen protocol
HACD - Setup Program

One Configuration Software for all Applications Editor for the Configuration of the Control Structure using predefined functions (programming knowledge not required) Clearly arranged Settings for commands, controller parameters, analog and digital I/O setup Oscilloscope Function also suitable as a data recorder Language Options English / Deutsch
Bus Controllers - HNC HNC Hydraulic Numerical Controller

32 Bit Multi-Axis Controller User Programmed using NC G codes Bus Capability
PROFIBUS Available CANOpen Available SERCOS - Available DeviceNet - In development
HNC Technology: Connectivity + Drive Control Options
HNC - Bus Applications
HNC with SERCOS interface
Robust SERCOS fiber optic interface
SERCOS interface Noise immune fiber optic ring connection Distributed drive architecture Mode: Closed-loop position control (SERCOS cycle time 2 ms) Preferred and freely configurable messages Special control algorithms for interpolating with electro-hydraulic drives HNC100 closes the control loop Digital interfaces for measuring system EnDat absolute, incremental, SSI Command value feedforward via Sercos HNC100 looks and acts like an electric servo to the CNC
HNC with SERCOS Interface

CNC control system solutions by Bosch Rexroth MTX
CNC control
MTC 200
CNC control
SERCOS (command value and actual value) Ecodrive IDIAX
additional axes can be added
SERCOS (command value and actual value) Ecodrive IDIAX
additional axes can be added
Electrohydraulic actuator controlled by the HNC Control and Power Electronics HRS (HNC 100)
Electrohydraulic actuator controlled by the HNC Control and Power Electronics HRS (HNC 100)
Electromagnetic motors
Electrohydraulic actuator
Electromagnetic motors
Electrohydraulic actuator
HNC Technology: Demonstration and Development Tools

The Test Box comes with three Prj.-Files: Demo_ana (analog Feedback) Demo_ink (incremental Feedback) Demo_abs (absolute SSI Feedback)
VT-HNC100DEMO Refer to RD/RE 30133


Proportional Valve, Limit Switches and Relay Logic
Proportional Valve and Linear Displacement Transducer

Closed Loop Position Control with Servo Solenoid Valve and Linear Displacement Transducer
Open Loop Systems vs. Closed Loop Systems
Closed Loop System Components

Setpoint Potentiometer Set Point Card PLC Analog Output Controller AVPC p/Q card DMX HACD HNC Amplifier Amp Card Amp Cube OBE Valve p/Q Overlap (W) Zero Lap (V)
Actuator Motor Cylinder Measuring Device Pressure Transducer Ultrasonic LVDT Encoder Potentiometer
The Three Most Common Types of Control

Position Control
Velocity Control
Pressure Control
Physics of Hydraulics
Hydraulic Stiffness Example: Apply a 1 ton load to a cylinder. The no-load position is 100 cm Compare the cylinder when filled with : 1. Oil 2. Water 3. Air 4. Steel
No Load
A = 10 cm2 100 cm
PL = 0 bar
Stiffness of Various Materials

1T X = 0.7 cm Oil 99.3 cm 1T X = 0.4 cm Water 99.6 cm
PL = 100 bar
PL = 100 bar 1T 1T X = 0.002 cm X = 99 cm Air 1 cm Steel 99.998 cm
PL = 100 bar
PL = 100 bar
Solving Stiffness Limitations
In order to maintain a fixed cylinder position independent of load changes, the following must be used: 1. Mechanical stops (metal to metal) or 2. Closed loop control
The same conditions are true for a constant velocity drive. Again the following solutions must be used: 1. Electric servo drive (Indramat) or 2. Closed loop hydraulic drive using load sense, load compensator or electro-hydraulic closed loop
Example of Position Control

1. Mechanical-hydraulic Closed loop
F
2. Electro-hydraulic Closed loop
Feedback F U Position Transducer S Error Command Controller
Control Valve
Improving the System Stiffness
A four-way valve controls both sides of an actuator.
As a result, the load is held between two springs. With this configuration, the spring-constant is higher ! Note: See Rexroth Hydraulic Trainer Vol. 2 or Using Industrial Hydraulics for more details.
Positioning with Higher Stiffness
1. Mechanical-hydraulic
2. Electro-hydraulic
What Impacts Machine Design ?

How does a real hydraulic drive differ from an ideal drive? Response
The ideal or linear drive converts all input (command) signals into output signals without delays or distortions. Examples of input signals can be: On / Off, Stop / Go Analog voltages PLC program I/O Example: A rod or a lever converts inputs directly into corresponding outputs.
In
Out
Spring Mass Systems Respond Differently

As we will see later, hydraulic drives are spring-mass systems. Spring-mass systems have two observable properties: 1. Natural frequency 2. Damping
Example:
1. The number of oscillations per second is the natural frequency fo 2. After time, the oscillation decays due to damping.
T=
1 fo
Predicting the Natural Frequency

The natural frequency is determined solely by: Spring constant C of the drive Mass M coupled to the drive C M
fo =
Why should the natural frequency be high as possible ?
A simple experiment will show: Every machine has mass and is not completely rigid. Consequently all machines are spring-mass systems. Take a machine axis with a given fo, and oscillate it between two defined positions, 0 and 10.
Machine Limits Imposed by Natural Frequency

If we move the axis slowly", the machine will respond ideally, i.e. it moves from 0 to 10, as commanded.
If we increase the number of cycles per second, the machine output will increase in stroke! This can be dangerous and destructive to the machine! Every machine has a limit of operation. If we exceed this limit, the natural frequency of the machine is approached, and the machine starts to resonate at that natural frequency. This MUST be avoided; BAD things will happen. http://timber.ce.wsu.edu/supplements/seismic/frequency.htm
Benefits of Damping
Increasing damping or, How to Control Resonant Response
If damping is increased in a spring-mass system, amplitude increase or overshoot can be reduced. The graph that follows shows how our experiment varies if we increase damping. To understand the effect, visualize the previous experiment with the moving components immersed in: Water (d 0.5) Honey (d 2) Hot tar (d 20)
Effect of Increased Damping
A damping ratio of d 0.7 results in the best overall response. Unfortunately, by increasing damping, another problem occurs: A time delay between the input and output, so-called phase-lag, increases.
Improving Damping
Note: A hydraulic machine drive will normally have a damping ratio between 0.05 ~ 0.4, and will respond accordingly. Proportional valves and servo valves are designed with damping ratios of 0.75. They exhibit no overshoot. How to increase damping: Dissipate kinetic energy by converting it into heat, known as passive damping (used in car shock absorbers) or; Actively counter the kinetic energy using a closed loop feedback to cancel oscillations, called active damping. Both methods are used in systems today.
What Creates Damping

Note: It would appear that increasing friction is a simple way to increase passive damping. This is a trap! Mechanical friction can be high at low speeds (breakaway friction), and lower at higher speeds (running friction). High breakaway friction deteriorates a systems performance and must be minimized! Use of low friction PTFE cylinder seals, lubrication, hydrostatic bearings, etc. is normally recommended for this reason. Passive damping is present due to internal leakage
FL1 p
= p
M LA
Laminar Flow
Passive Damping
FL1 p
tu =R rb
Sharp-edge Orifice
Turbulent Flow
Leakage caused by cylinder seal leakage, bypass valves, and valve null-flow, resulting from underlapped spools, improves damping.
Bypass Valve
Uo
Valve
Underlapped Spool
Disadvantages:
Loss of energy (efficiency) Decreased static accuracy
Active Damping
Example of Active Damping using Pressure Feedback
The (simplified) circuit shows an aircraft actuator in closed loop position control. A step-load can cause oscillation, dependent on the system gain. ( B lever ratio in this example)
A
Command
Modulator to Provide Active Damping

A so-called modulator is added to the system. Pressure increases caused by step-load changes allow the lever support to move. Response time and amplitude of the modulator piston is determined by an orifice and a small accumulator. A high damping is created with this type of control (P-DT1 control). This idea is 80 years old! In some applications today, an electronic equivalent is used, also known as active damping, or state variable control.
Modulator
Orifice Volume
Designing for Performance
Components When designing a hydraulic drive, it is essential to consider both static and dynamic characteristics of the drives. For example: If a constant load is applied to an actuator, it will deflect, as seen earlier. The spring constant of the drive is calculated as: E = bulk modulus of the fluid A = area of cylinder Vo = total compressed volume
E A2 C= Vo
Stiffness of Actuators F X F C
Therefore:
C= X =
F = load X = deflection
The result is the deflection under load, or the stiffness. If a load is suddenly applied to the drive, or the load is accelerated dynamically, it will respond like a spring - mass system, and the dynamic properties will be dominant. Selecting a cylinder should be based on both the static and dynamic requirements:
Defining Drive Requirements
1. Static:
- Balance of forces, i.e. the cylinder must have enough force to hold and move the load F = p A - Rod buckling must be considered. The cylinder attachment design or rod diameter should be changed if required.
2. Dynamic:
- The drive should have sufficient dynamic response to accommodate load changes and accelerations. As seen earlier in a bode-plot, a drive will appear to be rigid and have minimal adverse dynamic effects when operated below its limit frequency.
Determining Performance Requirements
When designing a hydraulic drive system, it is desirable to have the natural frequency as high as possible, while staying within the allocated budget.
Rule of thumb for good design: C M E A2 fo = , C= 2 Vo

A hydraulic designer can only improve the natural frequency of the drive by varying the cylinder size, and minimizing the pipe length between cylinder and the valve. NOTE: M (mass) is not measured in pounds in English units. Rather M(mass) = F (lbs)/A (in./sec2) = (lbs.)/(32.16 (ft./ sec2) x 12 (in./ft)) = (lbs.) / 386 (in./ sec2)
Design Guidelines
A quick approach for finding an optimal cylinder: 1. Calculate F = p A 2. Check for rod buckling Typical Arrangement
F
Single rod cylinder with pipe connections to the valve fo calculation is difficult
Simplified Approximation
A B
Equal area cylinder (added rod results in lower fo) Eliminate pipe volume by mounting valve directly on the cylinder (improve fo)
Rule of Thumb Selection

Assuming the two changes in the above approximation cancel each other, the value of Vo (cylinder centered) is:
Vo = AA S/2
Since:
AA = Annulus Area S = Stroke

Result:
fo =
C M
C = C1 + C2
E A2 C1 = C2 = Vo
fo =
2 E AA S/2 M
Vo = AA S/2
Typical Machine Requirements
Therefore:
fo2 2 S M AA = E
This formula provides an annulus area of the cylinder required for a desirable natural frequency. The following are experience based guidelines: fo < 4 Hz Poor dynamics, good static performance only fo 15 Hz Good frequency for general machine designs fo 30 Hz Needed for machines requiring high dynamics
Hydraulic Motor Estimation

The same rules apply to hydraulic motor drives:
fo2 4 4 I q= E
I = Rotating inertia
Note: If a difference of opinion arises, such as the machine designer insisting on using a small cylinder operating at high pressure, but calculations dictate a larger cylinder and lower pressures, you can compare the alternatives with a simulation program, such as HYVOS by BoschRexroth
Machine Considerations
MEFF = M (
m
x 2 y)
M x y
ATTENTION! In many designs, the mass M is not directly driven by the actuator.
JEFF
N out
Valve
N = rpm n=
N out N in
N in
In the examples shown here, the effective mass or inertia must be calculated. The effective value seen by the actuator (reflected inertia) is the (lever-ratio)2 or (gear-ratio)2 !
JEFF = J (n)2
x y
MEFF = M (
x+y 2 y )
Therefore:
fo =
C MEFF
JEFF = (
2 P
2 )
P = pitch =
in rev
JEFF = M (r)2
Machine Stiffness
Important Note: If the driven machine structure is flexible (typically the case), the result is a complex pair of 2nd order spring - mass systems (4th order and higher in most situations). Manual calculation of these systems is very tedious. Machine designers should always try to make the driven structure as rigid as possible. A goal is to have the natural frequency of the driven structure be 3 times higher than the hydraulic drives natural frequency. With this ratio, the machines dynamic response will have a minimal influence on the overall drive performance. When the ratio is 10:1, the machine can be considered a rigid structure, and not be a factor in the drives design.
Valve Sizing 1. Pressure Drop

Pressure drop (p) is defined as the difference between the system (pump) pressure and the load pressure. Load pressure can only be measured directly when a meter- in throttle circuit is used. Example 1:
pL Q AP F
F pL = A p pV = pP pL
PV pP = 100%
Pressure Drop with 2 Orifices

It is obvious that the pressure drop is not selected by the designer. It is a function of the system pressure and the load applied to the actuator.
Example 2:
pA pB
F
F p L = pA p B = A A p1 = p2 pv = 2 p1
(Also applies to Hydraulic Motors)
p1
p2
pP = 100%
Meter Out and Double Throttles Example 3:

pB
F
pP Ap F pV = pB = AA
P1
pP = 100%
AP = Piston area AA = Annulus area
Example 4:
pA
pB
F
pv = p1+ p2 for Q1 p1 = pP Ap F Ap + AA 2
p1
Q1
p2
Ap AA
pP = 100%
How to Find the Proper Valve
Flow ratings of proportional valves are the rated flow at a NOMINAL pressure drop, and normally have nothing to do with actually sizing a proportional valve. First, we need to calculate the ACTUAL pV for the specific system. After calculating the pV, refer to a valve data sheet. Example 4: Flow Pump-pressure Force Cylinder Q pP F Ap AA = = = = = = 450 l/min 210 bar 3600 daN 20cm2 10 cm2 2
Which Proportional Valve do we choose?
p1 = p1 =
pP Ap F Ap +
AA 2 1.6 in2 0000 22
(3000 psi 3.1 in2) 7920 LB 3.1 in2 +
p1 = 394 psi For a 2:1 cylinder ( = 2), we choose a 2:1 valve (QA:QB = 2), Then, p1 = p2 and: pV = 2 pV1 = 788 psi (= 54 bar)
RA 29 115 Page 13-14 4WRZ valve
WRZ 16 is too small WRZ 25 E 220 is 92% open WRZ 25 E 325 is 78 % open
Spool Flow Characteristics
Characteristic curves (measured with spools E, W6-, EA, W6A at v = 46 mm2/s and v = 40 C) Size 16 150 L/min nominal flow with a 10 bar valve pressure differential
121.5 105.7 84.5 63.4 42.3 21.1 0
(460) (400) (320) (240) (160) (80) 15 20 30 40 50 60 70 Command value in % 80 90

PA T / or PB T / B A
788 PSI
4 3 2 1
1 2 3 4 5
p = 10 bar constant p = 20 bar constant p = 30 bar constant p = 50 bar constant p = 100 bar constant
100
Spool Flow Characteristics

Characteristic curves (measured with spools E, W6-, EA, W6A at v = 46 mm2/s and v = 40 C)
211.0 185.0 159.0 132.0 106.0 79.3 52.8 26.4 0 (800) (700) (600) (500) (400) (300) (200) (100) 15 20 30 40 50 60 70 Comman d value in % 80 90 100
Size 25
220 L/min nominal flow with a 10 bar valve pressure differential

4 3 2 1 5
788 PSI
1 2 3 4 5
p p p p p
= 10 bar constant = 20 bar constant = 30 bar constant = 50 bar constant = 100 bar constant
230.0 211.0 185.0 159.0 132.0 106.0 79.3 52.8 26.4 0
(870) (800) (700) (600) (500) (400)
325 L/min nominal flow with a 10 bar valve pressure differential 5

4 3 2 1
788 PSI
1 2 3 4 5
p p p p p
= 10 bar constant = 20 bar constant = 30 bar constant = 50 bar constant = 100 bar constant
(300) (200) (100) 15 20 30 40 50 60 70 Co mman d value in % 80 90 100
p = Valve pressure differential to DIN 24 311 (input pressure pP minus load pressure pL minus return line pressure pT)
Data Sheet Ratings

As shown, the available pressure drop across the valve is a result of pump pressure and load pressure. Data sheets typically give a nominal flow at a nominal pressure drop. There are two de facto standards used in the hydraulics industry to define the flow through a control valve: Servo & High-Response Proportional Valves A pressure drop Pv = 1000 PSI (70 bar) is used. When the valve is open 100%, the measured flow is the nominal flow at 1000 PSI total pressure drop. Proportional Valves A pressure drop Pv = 145 PSI (10 bar) is used. The valve is opened from zero to maximum. The typically non-linear flow characteristic is recorded.
Pressure Drop Test Circuit
QNom
pP = 70 bar
Valve Pressure Drop Rating We use the sharp-edged orifice equation and the valve flow rating to determine the flow at the pressure drop of our system. Q2 = Q1 x (p2/p1) Example: If a valve is rated for 50 LPM @ 1000 PSI, the flow at 2000 PSI = Q2 = 50 lpm x (2000/1000) = 71 LPM
Valve Pressure Drop Selection

Since proportional valves often not linearized, a graph is generated for flow vs. spool-stroke. This also eliminates the need to calculate flows at various pressure drops. Instead, many data sheets will give a family of flows for various pressure drops: pv = 20 bar (290 PSI) 30 bar (435 PSI) 50 bar (725 PSI) 100 bar (1,450 PSI) Example: 4 WRZ 16 E 150 valve
121.5 105.7 84.5 63.4 42.3 21.1 0 (460) (400) (320) (240) (160) (80) 15 20 30 40 50 60 70 Co mmand value in % 80 90 100 QNOM
1
150 L/min nominal flow with a 10 bar valve pressure differential 5

4 3 2
1 2 3 4 5
p = Valve pressure differential to DIN 24 311 (input pressure pP minus load pressure pL minus return line pressure pT)
Sizing Proportional Valves for Acceleration and Deceleration
For transfer systems, the highest pressures are normally experienced during acceleration of the mass. The natural frequency of a hydraulic system normally determines the minimal allowable acceleration and deceleration. tmin (sec) = (3 x 6)/ o tmin o C M fo = o / (2 x )
= minimum time of acceleration (sec) = natural frequency, undamped (radians/sec) = (C/M) = spring constant = mass (NOT POUNDS)
Simulation Software
Above, we used an ideal 1:1 double-rod cylinder in order to simplify calculations and estimate natural frequency and an ideal annulus area:
E A2 C1 = C2 = Vo
fo =
2 E AA S/2 M
fo2 2 S M AA = E
Simulation software such as HYVOS allows extremely accurate simulation of the performance of hydraulic systems without the above simplification. But this software can be difficult to access. A simple spreadsheet, though, can quickly calculate many of the most important values necessary for design. Simplifications such as above then become generally unnecessary.
Poor Mans Simulation Software

Natural Frequency, 2:1 Cylinder, 1=a side, 2=b side, 2:1 Valve Bulk Mod (lb/in)= d-bore1 (in)= d-rod1 (in)= A1 (si)= 200000 2.00 0.00 3.14 Weight (lb) = Mass (lb*ss/in)= C (friction)= 700.00 1.81 1.00 V-max (in/sec)= d-bore2 (in)= d-rod2 (in)= A2 (si)= 2.00 1.38 1.66 w(theor)(rad/sec)= w(damp)(rad/sec)= stroke (in)= d-pipe 1 (in)= L-pipe 1 (in)= d-pipe 2 (in)= L-pipe 2 (in)= V-pipe 1 (ci)= V-pipe 2 (ci)= 42.00 0.63 48.00 1.00 48.00 14.72 37.68 F (accel) = F (friction) (lb)= 610.06 700.00 dP1 = d-crit (in)= 35.54 dP2 = dPt= Cmin= 26,947 367.3 408.6 775.9 489.8 544.8 1034.6 612.2 681.0 1293.2 t(min. accel.) (sec)= 0.15 P3 (psi)= P2 (PSI)= Accel. 408.6 632.7 Const. Vel. 544.8 510.2 Decel. 681.0 387.8 t (time cont)(sec)= 0.02 P-system (psi)= 1000.0 121.96 40.65 F-acceler (lb)= F-friction (lb) = 610.1 700.0 Ct (lb/in)= 26,947 A-max (in/ss)= 49.7 336.8 Valve Pressure Drops Required Stroke (in)= t (stroke) (sec)= 20.0 0.6 Qmax= 40.5
Proportional Acceleration Systems
Remember: Total pressure drop can be greater than system pressure, especially if the valve ratio does not match the cylinder ratio A negative pressure in one or the other side of the cylinder means that cavitation will occur. Again, this normally occurs if the ratios do not match. Infinite acceleration is not possible, so actual velocity and flow will be greater than average velocity and flow. Size valve accordingly. Reducing volume between the valve and cylinder will increase spring-constant C, and allow for faster acceleration. Larger bore cylinders also increase spring-constant C. If natural frequency is too low, theres always state control. But figure this out before start up!
Oversizing and Undersizing of Valves
Design Example:
Two engineers select the valve and the pump (system) pressure setting for the same application. Engineer #1: calculates PL = 66 bar for load pressure Engineer #2: calculates same as above Engineer #1 sets the pump pressure to 100 bar. Therefore the valve pressure drop is Pv = 33 bar. A valve is selected from the catalog that passes the required flow at a pressure drop of 33 bar, when the valve is fully opened.
Valve Selection Example

Engineer #2 selects a valve which has a flow rate twice that of Engineer #1s choice (for example, 200 liter spool instead of 100 liter spool). It will have the same flow with 1/4 of the pressure drop across the valve. Engineer #2 sets his pump pressure to Pp = 74 bar. The valve pressure drop is only 8 bar rather than 33 bar! (see graph)
Design Note:
Engineer #2 will have a more efficient system, suitable for non-dynamic systems. If dynamic acceleration and decelerations are required, a higher pressure drop will result in better control. The electrical command to the valve will be more accurately followed when a higher pressure drop is used.
Pressure Drop Relationships

Q = Flow F = Force v = Velocity P = Power pL = Load pressure p = Valve drop
P=Fv P = pL Q
Engineer #2
200%
pL = 66 bar (11/12) (1/12) pv = 8.5 bar pP = 74.5 bar (12/12) Q, v pL p

8%
Engineer #1
pL = 66 bar (2/3) pv = 33 bar (1/3) pP = 100 bar (3/3)

100
Q, v pL p
2/ 3 33%
Q, V, pL, 50 p, P
0
P
92%
P
50
2/3
66%
100%
50 F
2/3
11
100%
/12
Effect of Valve Response

In open loop applications, a main valve selection criteria is that the valve responds accurately to the command signal. Valve shift times in the data sheet should be compared to the required response times.
Example: 4 WRZ 16 . . .
100
Transient function with a stepped form of electrical input signal Model 4WRZ... Signal change in %
0 100
75
0 75
50
0 50
25
0 25
0 0 30 60 90 120 150 0 30 60 90 120 150

Time in ms Time in ms
In most open loop systems, the dynamic properties of the system dictates the overall system performance. The effects of valve hysteresis and threshold become more critical when Closing the Loop.
Closing the Loop

An undesirable characteristic of most hydraulic systems is that the relationship between the command signal and the output of a hydraulic drive is not a linear (proportional) function. - Valve response to a stepped electrical signal is:
Transfer function: Stepped electrical input signal
Size 6
100 90 80 0-75 70 60 50 40 30 20 10 0 40 80 120 160 200 Time in ms 0 40 80 120 160 0-25 0-50 Signal change in % 0-100
Proportional valve type: 4WRA6...
(A servo valve would respond similarly but up to 10 times faster)

Cylinder Response
Cylinder response to a stepped input (flow Q) is: Servo Valve
i
Q
Cylinder
(X) v X
Two characteristics are observed:

1) A cylinder with an attached mass responds as a spring - mass system
2) An integration occurs between the input and output. This results in a phase-lag of -90
Example of Phase-Lag
If the cylinder stroke versus the valve command signal (valve spool stroke) is plotted, the phase-lag can be seen:
0 90
180 270 360
In this example, the valve and cylinder are in open loop. Note: As the valve is operated at increasing frequencies, the phaselag increases due to inertia and spring compliance Important: If -180 total phase-lag occurs in the system, the output will be inverted as compared to the command signal!
Closing the Loop Mechanically

F
Feedback
Command
When a feedback (lever mechanism in this example) is added, the system responds in a proportional manner rather than as an integrator. Response to a step is similar to the response of a valve spool, proportional with some time lag (known as PT1).
Gain of the Closed Loop
If the pivot on the feedback lever is moved to the left, the amount of valve spool opening is increased for the same position error. The system corrects for errors faster, and the positional accuracy improves. If we move the pivot more and more to the left (more gain), the system response will exhibit increasing overshoot, and eventually become unstable.
Example: X
t Low Gain High Gain
t Too High Gain
Closing the Loop Electrically

Controller F Feedback Transducer S U Control Valve Command Amplifier
This example is essentially the same as the mechanical feedback example shown before. The ultimate system performance (response time and accuracy) is determined by the properties of all components in the system.
Properties of the System Components
1. Cylinder
An ideal cylinder would have zero breakaway friction and no internal leakage. In actuality, cylinder friction results in positioning errors (cylinders exhibit stick-slip friction at low speed). Additionally internal cylinder leakage will result in a compensating flow (spool shift) in the valve. These limitations cause position errors.
2. Feedback Transducer
An ideal transducer would measure infinitesimal position errors for the controller to correct. An actual transducer has limited resolution, which results in a position measurement error. The response time of some transducers can also cause signal delays, which can limit system response.
Properties of System Components 3. Valve

An ideal valve would have zero response time and react to any input signal. Real valves have step response times as seen, and require some minimum signal to respond, known as threshold. Additionally, a true zero-overlap spool, as shown in the examples, is only possible with poppet type valves. Since spool valves are normally used, a zero-overlap spool has null flow leakage in the center position. A hydraulic designer must therefore select the best available components, within his budget, to achieve the highest static accuracy possible.
Component selection for Overall System Performance
Ultimately the system performance is determined by the quality of all of the components used. What system improvements and tricks can be used to get the most out of a system? What can be done to optimize the system: The goal is to use the highest gain possible to achieve the highest accuracy, and the fastest response time.
Cylinder Selection Guidelines

1. Select a cylinder with: - Lowest friction seal material (PTFE composite, step seals, metal rings, etc); or for highest performance applications, a servo cylinder with hydrostatic bearings. - A cylinder size selected for high natural frequency, as well as for force and buckling. Except for the piping length between the cylinder and valve (best design is the valve mounted directly on the cylinder), the piston area is the only variable for increasing the natural frequency!
C M
fo =
E A2 C= Vo
Valve Selection Guidelines 2. Select a valve with:

- Minimum threshold and hysteresis (highest performance valves use electrical spool feedback) - A pressure drop as high as possible under nominal load conditions (at least 30% of the supply pressure) - Utilizing as much spool stroke as possible, with some reserve margin - Spool center position zero-lapped for position and under-lapped for pressure control - Overlapped proportional valves may only be used with appropriate control compensation features. (DMX, HNC) - Overshoot-free step response - Dynamic response determined by the application (highest available response is not always the best choice) - Special spool, if required
Example of a Special Spool for Plastic Injection Axes Velocity and Pressure Control
Transducer and Controller Selection Guidelines 3. Select a transducer with:

- Resolution five to ten times better than the required accuracy - Good linearity - Minimal time lag (high dynamic response)
4. Select a controller with:

- Highest possible resolution - Fastest scan time, if digital - Control algorithms optimized for hydraulic drives: direction-dependent gain, switched integrator for positioning, spool linearization and overlap compensation, following error compensation, P-I-DT1 controller, etc
Performance and Stability
5. Improve the System Damping Stability criteria defines the maximum system gain (goal for performance) as:
Kvmax < 2 D 2 fo Kvmax = Gain [ m/s ] m D = Damping Ratio fo = Natural frequency What are some ways to increase the system gain ?
Increase the Damping Ratio D by using: 1. 2. Passive damping Active damping
Increasing Damping
If velocity feedback is added to the position control, the closed loop frequency response can be increased. However, this results in reduced damping. This can cause reduced performance in some hydraulic closed loop systems. If acceleration feedback is added, the system damping will be increased. Load pressure feedback provides similar results when applied correctly. Using these feedbacks to improve performance is known as active damping or statevariable control.
ma=PA a~P
The modulator shown earlier is an excellent example of improving damping by using pressure feedback !
m = mass a = acceleration P = pressure A = cylinder area

Observer Control
In some systems, a so-called observer control is used. The dynamic response of the system is stored in an electronic model of the system (analog or digital). From this stored model, calculated values for velocity and/or acceleration (the state variables) are derived without using actual transducers.
1) Closed loop with position feedback
Command Controller
Gain fo D
Gain fo D
X = Position X = Velocity X = Acceleration

X X
Valve
Cylinder
Damping with Transducers
2) Closed loop state variable control using position, velocity and acceleration transducers
Gain fo Gain D fo D F
Command Controller
Valve
KX
Acceleration
Cylinder
KX
Velocity
Damping with Observer Model Values

3) Closed loop using calculated values for velocity and acceleration
Command
Gain fo D
Gain fo D
X
Cylinder
Controller
Valve
KX
XM
Acceleration
KX
XM X - XM XM
Velocity
Observer Model Model Corrector
Using Integrators
In theory, using an integrator in the controller would result in perfect accuracy (any deviation from the commanded position would result in an increasing opening of the valve spool). However, due to friction and threshold errors, a continuous integration limit cycle oscillation can occur.
An integrator also results in an additional -90 of phase lag. This can cause a hydraulic positioning axis to becoming a high power phase shift oscillator
In practical use, an integrator is enabled only below a preset minimum velocity, and when within a position error "window" (switched integrator).
Along with electronic spool overlap compensation, high accuracy results can be achieved using simple, low cost proportional valves, in closed loop.
Supply Pressure Considerations

1. Supply Pressure
The system pressure should be constant. When high flow is required (high system dynamics), a drop in supply pressure can occur due to acceleration of the oil mass in the lines, and due to the response time of the pumps pressure control.
Recommendation: An accumulator should be used in the pressure supply, mounted near the control valve.
If the system has a long return line, similar problems may occur. Acceleration of the return oil mass can cause return pressure spikes, which reduces the available working pressure. This will reduce the system performance.
Recommendation: Use return line accumulators near the control valve, as needed.
Supply Pressure Optimization
Using accumulators to improve dynamic response.

P
M
S
Note: The mass of the oil in the return line can have a very significant effect !
Valve Dynamic Selection
There are three general configurations of valve-cylinder dynamics: Case 1: Case 2: Case 3:
The valve is high response and the cylinder is low response (fo ) The valve and the cylinder are similar in response The valve is low response and the cylinder is high response (fo )
focyl fov
= natural frequency of the cylinder = natural frequency of the valve
Relationship of Valve and Cylinder Dynamics

State-variable Controller PT1 Controller P Controller PDT1 Controller
0.3 Case 1
0.6
1.0 Case 2
1.7
3.0 Case 3
focyl Case 1: f 0.3 - Best results are achieved with pressure ov

or acceleration feedback
focyl 1 - A simple PT1 controller offers best results fov Case 3: focyl 3 - A PD controller will provide best results fov Case 2:
Effect of Controller Parameters

The following graphs show step response for all three cases. The parameters are varied per: 1. Increase P Gain, left to right 2. Increase, bottom to top :
Case 1: Acceleration feedback Case 2: Lag time T1 Case 3: Derivative gain
Effect of Parameters Case 1
Increased P-Gain
Increased Acceleration Feedback
Increased P-Gain
Increased Lag Time T1
Increased P-Gain
Increased Derivative Gain D
Performance Optimized with Parameters
In the examples shown, it can be seen that a higher gain can be achieved when other compensating parameters are used. By using higher gain, increased accuracy and improved response is achieved, and stability is maintained.
Other Considerations on System Dynamics Note: Case 1: Fast valve - slow cylinder, is an example of a classic
servo system, using a servo valve. Optimally, a double-rod, equal area cylinder should be used.
Case 3: Slow valve - fast cylinder, is a typical application using low

cost proportional valves, operating in closed loop. The control performance is not perfect, but can usually meet the design requirements. Due to the proportional valves spool overlap and nonlinear flow characteristics, as well as the fact that differential cylinders are most often used, the controller must compensate for these properties. Controllers such as the HACD and HNC-100 utilize these compensations. Proportional valves can provide a low cost solution with good accuracy, long life, and simple maintenance.
Closed Loop Application Using a Proportional Valve and a Differential Cylinder

Encoder Feedback Incremental Signal
s in mm m v m/min
Cylinder
Proportional Valve
Amplifier
CNC Feedback
Q L/min A
UCNC 10V
Command s
Output stage Q in L/min v in m/min
Control UCNC in V
D/A Control
Kv Q
Kv UCNC
Kv s + s in mm CNC Gain Kv =
UCNC
UCNC
Drive Gain Kv =
v m/min in Q L/min
Q in L/min
Electrohydraulic Gain Kv =
Q in UCNC L/min V
UCNC in V
v in m/min
+Q in L/min
+ UCNC in V
in
V mm
21.1
(80) (60) (40) (20)

PA T / or PB T / B
Loop Gain Kv = Kv CNC Kv El-Hy Kv Drive Kv FB in
15.9 10.6 5.3
m min mm
A
3 2 1
10
20
30
40
50 60 70 Command value in %
80
90
100
1 2 3 4 5
Electronic Compensation of Non-linear Flow Characteristics and Valve Spool Overlap

Standard
I
Output signal
Linearization Compensation Linearization and Overlap

I
Output signal
Output signal
Amplifier
-U
+U
-U
+U
-U
Controller signal
Resulting signal
+U
I +Q
I +Q
I +Q
-U -Q Valve
Positive overlap
+U
-U -Q
Positive overlap
+U
-U -Q
Positive overlap
+U
Overall System Characteristics
The following pages show examples of system response, in open and closed loop. System response is shown with step and ramp command inputs, step input opposing force, and the effects of various controller elements.
Elements of an Open Loop System
Cylinder
State Variables
X = Position X = Velocity X = Acceleration
PB
PA
Valve
I V
Command Generator
PS
PT
Valve Driver
Spool Opening
Open Loop Response to a Step Input

X
Cylinder
PA
PB
Valve
I V
PS
PT
Valve Driver
Spool Opening
Command Generator
Open Loop Response to a Force Step
Cylinder
F
PA PB
Valve
I V
PS
PT
Valve Driver
Command Generator
Spool Opening
Elements of a Closed Loop System

Transduce r
X
Cylinder
Transduce r Interface PA Valve PB
I V
PS
PT
Valve Driver
Command Generator
Controller
Spool Opening
Closed Loop Response to a Step Input

Transducer Cylinder
X
Command Feedback
Transducer Interface
PA Valve
PB
I V
PS
PT
Valve Driver
Controlle r
Command Generator
Spool Opening
Valve Signal
Effect of P Gain on Position Control
Position
Gain 3 Gain 2 Gain 1 Gain 1 > Gain 2 > Gain 3
Transducer Cylinder
PA Valve
PB
Time
Gain Controller
Command
Velocity
Valve Driver PS PT Spool Opening
Time
Closed Loop Response to a Ramp Input

Transducer Cylinder
X
Command Feedback
Transducer Interface PA Valve PB

X
I V
PS
PT
Valve Driver Valve Signal
Controller
Command Generator
Spool Opening
Dynamics and Errors in Closed Loop

Position Error Following Error
Command Feedback
Position
Response to a Ramped Position Command
Time
Phase Lag Amplitude Loss
Position
Response to a Sinusoidal Command
Closed Loop Response to a Force Step

Transducer
Command Feedback
Cylinder
F
PA Valve
PB
I V
PS
PT
Valve Driver
Controller
Command Generator
Spool Opening
Position Control - Correction for Opposing Force using PI Control

Force Position Error
P Control
Feedback
Position
Command Feedback
Out P Gain
Command
Time
Force
PI Control
Feedback
Position
Command Feedback
Out P Gain + I Rate
Command
Time
Response of a PID Controller to a Step Input
P Term Time
Input Time I Term Time
Output Time
D Term
Time
Response of a PID Controller to a Ramp Input

P Term Time
Input Time I Term Time
Output
Time
D Term
Time
Position Control - Improving Dynamics using PD Control

P Control
Feedback
Position
Gain 2 Gain 1 Gain 1 > Gain 2
Out P Gain
Command
Time PD Control
Feedback Gain 2 Gain 1 Gain 1 > Gain 2
Position
Out P Gain + D Lead Time
Command
Time
Position Control - Improving Dynamics using PT1 Control

P Control
Feedback
Position
Out P Gain
Command
Time Position
PT1 Control
Feedback
Out P Gain + Lag Time
Command
Time
BoschRexroth Proportional Valves
Which Proportional Valve should I use?
Start here
Low Flow (Direct Operated) Open Loop (No Cylinder Feedback)

4WRAB Flows to 25 Lpm, minimum cost, limited performance (similar to KDG4V-3 S) 4WRA Greater flow range to 60 Lpm, better performance, more features (Ramp) 4WRAE6 4WRAB6
4WRAE10
Low Flow (Direct Operated); Open Loop with Better Performance (No Cylinder Feedback)
4WRE(E) Designed for good performance without high cost Very repeatable Greater flow capacity High value 4WRP(E) Proportional with LVDT 5 bar/ land or 10 bar delta-p, E and W spools in housing (no sleeve) Overlap compensation High reliability Most robust OBE available CE approved
4WREE10
4WRPE10 E Proportional
High Flow (Pilot Operated) Open Loop (No Cylinder Feedback)

4WRZ Wide flow range, Cost effective, Accurate enough for most open loop needs 4WRL (HPP) with overlap E and W spools, OBE has overlap comp., High dynamics, Most robust OBE, CE approved
4WRLE (HPP) High Performance Proportional
4WRZE
Low Flow (Direct Operated) Closed Loop (Cylinder or system Feedback)

4WRP H - Servo Solenoid Best Choice, Excellent dynamics for closed loop, Failsafe defined, Outperforms many old servos, Very Robust OBE, High reliability, Wide range of nominal flow 2 to 100 Lpm at 70 bar (Higher delta-P for Spool/sleeve valve) 4WRE Wider flow range, spool in housing (normally V), proportional flow rating, lower cost, Performance not as high
4WRPEH 10
4WREE10
High Flow (Pilot Operated) Closed Loop - System Feedback

4WRLE Servo Solenoid with V-spool, High Flow range, Main spool in housing, Flow rated at 10 bar delta-p, Very Robust OBE 4WRVE (HRV 2-Stage) Higher dynamics, 10 bar drop, Very Robust OBE, 12-pin Connector 4WRLE (Servo Solenoid 2 stage)
4WRVE (HRV - 2 stage)

Injection Valves are Preferred
4WRLE..Q4 Best choice for Injection valve for Plastic Injection Molding Machines Can replace Q2-spool High reliability Better Performance Same advantages of Servo Solenoid valves 4WRLE..Q4.-3X/
pQ Valves are Preferred For Closed Loop Pressure and Throttle Function
5WRPE (pQ Valve) Can combine double port throttle and 3-way for close loop pressure control, Requires transducer and PID card, 140 Lpm at 11 bar Note: Use P1+B to P2+A to balance flow forces, pmax is 210 bar
0 811 402 107


Hydraulic Proportional Control - Bosch Rexroth

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Design & Control of Proportional and Servo Systems

History of Hydraulic Control

Flow Controls, Limit Switches and Relay Logic

VT-MACAS (AVPC) Analog Velocity Position Control / V or mA

VT-MACAS (AVPC) Analog Velocity Position Control / V or mA

VT-MACAS (AVPC) Schematic

P/Q Cards with Valve Amplifier

P/Q Cards for Valves with OBE

P/Q Card Applications

Controller for the Pressure Difference (Force Control)

HACD Technology: European + American Product Experience

1997 to 2003 Joint Development

Bus Controllers - HACD

HACD - Setup Program

Bus Controllers - HNC HNC Hydraulic Numerical Controller

HNC Technology: Connectivity + Drive Control Options

HNC - Bus Applications

HNC with SERCOS interface

Robust SERCOS fiber optic interface

HNC with SERCOS Interface

SERCOS (command value and actual value) Ecodrive IDIAX

additional axes can be added

SERCOS (command value and actual value) Ecodrive IDIAX

additional axes can be added

HNC Technology: Demonstration and Development Tools

VT-HNC100DEMO Refer to RD/RE 30133

History of Hydraulic Control

Proportional Valve and Linear Displacement Transducer

History of Hydraulic Control

Open Loop Systems vs. Closed Loop Systems

Closed Loop System Components

The Three Most Common Types of Control

Stiffness of Various Materials

PL = 100 bar 1T 1T X = 0.002 cm X = 99 cm Air 1 cm Steel 99.998 cm

Solving Stiffness Limitations

Example of Position Control

2. Electro-hydraulic Closed loop

Feedback F U Position Transducer S Error Command Controller

Improving the System Stiffness

A four-way valve controls both sides of an actuator.

Positioning with Higher Stiffness

What Impacts Machine Design ?

Spring Mass Systems Respond Differently

Predicting the Natural Frequency

Why should the natural frequency be high as possible ?

Machine Limits Imposed by Natural Frequency

Effect of Increased Damping

What Creates Damping

Modulator to Provide Active Damping

Designing for Performance

Defining Drive Requirements

Determining Performance Requirements

Rule of thumb for good design: C M E A2 fo = , C= 2 Vo

Rule of Thumb Selection

AA = Annulus Area S = Stroke

Typical Machine Requirements

Hydraulic Motor Estimation

Valve Sizing 1. Pressure Drop

Pressure Drop with 2 Orifices

Meter Out and Double Throttles Example 3:

AP = Piston area AA = Annulus area

How to Find the Proper Valve

Which Proportional Valve do we choose?