Servovalve, Hydraulic Position Control

Sections:
1. Introduction
2. Component Considerations
3. Position Control System Dynamic Sizing
4. Position Servosystem Accuracy Calculations
5. Design Considerations to Improve Performance

1. Introduction
The objective of this section is to provide a basic understanding of an electrohydraulic position control
servosystem and to provide necessary equations to estimate performance characteristics. Having a
basic understanding of the equations behind the design will help selection of appropriate system
parameters. A position servosystem has been selected since it is the most common type
implemented.
An electrohydraulic position control servosystem can be defined as an electrically controlled hydraulic
actuator that automatically and accurately follows a position command.
Figure 1.1 illustrates a simplified electrohydraulic position control servosystem. It consists of a
hydraulic actuator, electohydraulic servovalve, electrical position sensor, and electronic controller.
See the Servovalve, Hydraulic - Description for a description of the servovalve internal workings. A
simplified description of operation is summarized here.
Figure 1.2 is a simplified control system block diagram of the electrohydraulic position control
servosystem. This block diagram neglects position sensor dynamics, servovalve dynamics, and the
load mass dynamics.
Using Figures 1.1 and 1.2 as a reference, control starts when a position command voltage signal is
input into the control electronics. The control electronics takes the position command and subtracts
the actuator measured position voltage signal. This sum, or position error signal as it is called, is then
multiplied by an electrical gain (Ka) in order to generate a current command to the servovalve. The
servovalve spool responds to the position error signal proportionally, in that the larger the error
signal the more the servovalve spool will travel, until it contacts its mechanical stroke limit. As the
servovalve spool moves the metering orifices in the valve open and provide flow paths to and from
the actuator, causing the actuator piston to move in the direction of command. As the actuator
position moves the position error signal calculated in the electronic controller gets smaller and
smaller. This results in the servovalve current decreasing which tends to close the servovalve flow
paths to the actuator. Once the measured actuator piston position equals the commanded position
(zero error signal), the servovalve flow paths are closed and the actuator piston is stopped (for a
description of servovalve operation, see Servovalve, Hydraulic - Description).





Figure 1.1 Schematic Diagram of a Servovalve Position Control System




Figure 1.2 Simplified Block Diagram of a Servovalve Position Control System

A position control servosystem can also be a completely mechanical device as shown in Figure 1.3.
In this figure the input command is a lever displacement which in turn moves the control valve spool
resulting in the valve opening flow paths to the actuator. The mechanical input, x
command
, is connected
via mechanical linkage to the cockpit controls (column, control wheel or rudder pedals). As the piston
moves the valve will start to close, and a new equilibrium established. Figure 1.4 is a simplified block
diagram of a mechanical servosystem for the system shown in Figure 1.3.





Figure 1.3 Schematic Diagram of a Mechanical Feedback Position Control System





Figure 1.4 Simplified Block Diagram of a Mechanical Feedback Control System



2. Component Considerations

Actuator and Servovalve Sizing
Reference Actuator, Hydraulic - Sizing to calculate the initial actuator hydraulic areas required to
move the load. Actuator stiffness and natural frequency can be calculated once the areas are known.
Then to correctly size the servovalve, calculate the actuator chamber pressures using the previously
calculated actuator areas. Once the chamber pressures are known, the servovalve required flow rate
can be determined. This information is required when sizing the position servosystem.

Servovalve Dynamics Considerations
Servovalve dynamics are important part of the analysis. Dynamic response data, often called
frequency response data, for a servovalve is generally provided by the servovalve manufacturer. A
frequency response graph is the relationship of the servovalve output flow to a constant amplitude
sine wave input current command which is swept over a range of frequencies.
Generally the servovalve frequency response can be adequately described as a second-order
response with a damping ratio between 0.8 and 1. A comparison can be made between a
manufacturers servovalve frequency response graph to a standard second order transfer function
curves to approximate the servovalves natural frequency and damping ratio. Vendor catalogs
typically provide natural frequency and damping ratio data for a selected servovalve.
When approximating a servovalve frequency response to a second order transfer function an
adjustment between the servovalve supply pressure used to generate catalog data and the
servosystem supply pressure used in your application must be made. Some servovalve vendors
provide an approximate factor to correct for supply pressure differences. If the servosystem is
operating at a supply pressure above what the servovalve was frequency response tested then the
frequency response data provided by the manufacturer can be used directly, as this will be
conservative. If the servosystem pressure is lower and a vendor factor is not provided, use an 80%
factor on the natural frequency obtained from vendor data (no factor is required on the damping ratio).
Note, a servovalve frequency response is far better behaved than the typical frequency response on
an actuator/load response; that is its does not exhibit a large gain at its natural frequency. This is
because servovalves second stage spool position control loop is designed to be reasonability
damped. Many of the same design considerations listed in this module are also used when designing
a servovalve.

Servosystem Natural Frequencies
Every component in the servo loop has a natural frequency (servovalve, actuator, controller, position
sensor, attachment bracket/structure). Generally the two lowest natural frequencies in a servosystem
are the load mass/actuator combination and the servovalve. Components with natural frequencies far
higher than the lowest natural frequency in the system will have little performance impact on the
dynamic characteristics of the servosystem and can be safely ignored when estimating initial
performance. The position sensor dynamics can also be ignored if its natural frequency is ten times
the lowest natural frequency in the servosystem.
If the actuator mounts to structure have the same or lower stiffness as the actuator hydraulic stiffness,
then this will introduce another natural frequency which would be lower than the actuator/load natural
frequency. This lower frequency will have to be included in the analysis.
The controller response should be relatively fast, again 10 times the frequency response of the lowest
natural frequency in the servosystem.

Position Transducer


The position transducer senses the actuator position and sends an electrical signal to the controller.
The characteristics of the transducer are very important in assuring a well designed servosystem. If
possible the transducer should be located as close to the actuator itself. Many designs actually
incorporate the transducer inside the hydraulic actuator itself. If the transducer is remotely mounted,
the structural stiffness between the position sensor and the actuator could lead to the introduction of
other natural frequencies into the servosystem. In this case, the structural mount stiffness would
need to be included in any analysis.
Position sensor items to consider are accuracy, resolution, hysteresis, and dynamic response. A
general rule for a transducer is it should have a natural frequency at least ten times higher than the
lowest natural frequency component components in the system.

3 Position Control System Dynamic Sizing

Servosystem Open Loop Gain
The actuator/load natural frequency usually limits the maximum gain in a position control system. In
some instances, the servovalve natural frequency will be the limiting factor on open loop gain. This
section presents closed loop performance optimization through selection of the controller gain. It
should be noted there are other compensation techniques that can be implemented to improve a
servosystem response, some of which will be covered later in this section.
To determine an initial estimate of open loop gain use the lower value calculated from the two
equations below. This will yield a conservative overall loop gain and should result in acceptable
performance. These equations are based on industry experience and control system analysis. If the
actuator natural frequency limits, the open loop gain can only be a fraction of the actuator frequency
since actuators tend to be very lightly damped. If the servovalve natural frequency limits, the open
loop gain can be higher since the servovalve damping is significantly higher than the actuator.
a) K
open
1
= 0.1
load _nat _ freq
(3.1)
b) K
open
2
= 0.4
servovalve_nat _ freq
(3.2)
Open loop gain is calculated by multiplying all the terms in the servosytem loop shown in Figure 3.1
from x
error
to x
feedback
(ignoring the Laplace variable s). The open loop gain is a measure of how much
velocity will be generated for a given position error. Figure 3.1 is essentially the same as Figure 1.2
in Section 1, with the exception that variables are in the blocks instead of a written description.



Figure 3.1 Simplified Control Diagram for a Servovalve Position Control System



Figure 3.1 and the analysis below uses Laplace notation. In Laplace notation s = +j, where j = 1
and is frequency in radians/second. A (1/s) in Laplace notation is an integrator. The open loop
gain is computed as (ignoring the Laplace variable s)
K
open
=
K
a
K
q
K
f
A
(1/sec) (3.3)
Once K
open
is determined, all the servosystem gains are known except K
a
, so we need to solve for K
a
.
K
a
=
A K
open
K
q
K
f
(amp/volt) (3.4)

If K
a
is too large, the servosystem position output will tend to oscillate when x
command
is a step
command. See Figure 3.2 for typical step responses as a function of damping ratio. K
a
calculated
from equation 3.4 is generally conservative and may need to adjusted. For example, increasing K
a
will
yield a faster response with a small amount of overshoot (<10% overshoot for a step input is a good
servosystem guideline, or a damping ratio of 0.7 or better). Adjustments are made during further
analysis, simulation, or testing to optimize the response. If the required performance is not obtained it
may be necessary to add compensation to the control architecture (see Section 5 for more
information).



Figure 3.2 Unit Step Response Of A Second Order System

The block diagram in Figure 3.1 can be simplified into a first order transfer function as follows. The
general first order transfer function is defined as:


X
position
X
command
=
G(s)
1+ G(s)H(s)

(3.5)
where s is the Laplace variable and
G(s) =
K
a
K
q
A s
H(s) = K
f
(3.6)
Note, G(s) is called a transfer function and is essentially a gain that varies as a function of frequency.
Note K
f
is a gain that does not vary with frequency (so H(s) does not vary with frequency).
Substituting parameters into (3.5) and simplifying
X
position
X
command
=
1
K
f
A
K
a
K
q
K
f
|
\

|
.
|
|
s +1
=
1
K
f
1
K
open
|
\

|
.
|
|
s +1
=
1
K
f
s +1
(3.7)
where
=
1
K
open
seconds
Here the servosystem dynamics approximate a first order system with a time constant of (1/K
open
).
For a step command the output would be 63% of its commanded value after one time constant.
For example, equation (3.8) below is a first order system with a time constant of 1. If a step input
(X
command
= 1) is applied at time=0, X
position
will equal 0.63 at time =1 seconds, equal 0.95 at time=3
seconds, and equal 0.99 at time = 5 seconds. See Figure 3.3 for a time response plot.

X
position
X
command
=
1
s +1
where: = 1 (3.8)




Figure 3.3 First Order System Response to a Step Input

For the steady state condition (s=0) we obtain,
X
position
=
1
K
f

(
(
x
command
(3.9)
Remember the first order transfer function obtained above neglects the servovalve and actuator/mass
dynamics. If the servovalve frequency is considerably more than the actuator natural frequency then
the servosystem response will approximate a first order transfer function system with a time constant
of (1/Kopen). As discussed in Servovalve, Hydraulic Sizing, the servovalve natural frequency
should be at least 3 times greater (faster) than the hydraulic natural frequency for the actuator/load
combination.

Servosystem Control Gain Example

For this example, define the natural frequency of the actuator/load and servovalve as follows:
Actuator natural frequency:
load _ nat
= 522 rad/sec
Servovalve natural frequency: f
natural
= 60 Hz, =0.8

Convert servovalve natural frequency into radian per second:

valve
= 2 f
valve
= 260 = 377 (rad/sec)
Determine the open loop gain:
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0 1 2 3 4 5
Time (seconds)
X
p
o
s
i
t
i
o
n

/

X
c
o
m
m
a
n
d


Kopen
1
= 0.1*
load _ nat
= 0.1*522 = 52
Kopen
2
= 0.1*
servovalve _ nat
= 0.4 * 377 = 151
Select the lowest K
open
to use in calculating K
a
:
K
a
=
A K
open
K
q
K
f
(mA/volt) (3.10)
where:
K
open
= 52
(sec-1 ) lowest K
open
calculated above
A = 1.5 (in
2
) use average of bore and rod areas
K
f
= 1 (volt/inch) Position sensor gain (volt/inch)

Let the servovalve have a rated flow of1.34 in
3
/sec at 10 mA input current with a supply pressure =
1000 psi. Assuming the servovalve operates at a supply pressure of 3000 psi, the flow gain needs to
be ratioed by the square root of supply pressure to the rated pressure (square root comes ratioing
two orifice flow equations at the different supply pressures).
K
q
=
1.34 *
3000
1000
10
= 0.232
in
3
sec
|
\

|
.
|
mA
servovalve flow gain
Equation (3.10) then becomes
K
a
=
AK
open
K
q
K
f
=
1.5 *52
0.232 *1
= 335 (sec
-1
) (3.11)
This calculated controller amplifier gain would be used in the position control servosystem when
initially setting up the system.

Computer Simulation
The previous analysis is simplified in that the various gains in the system are linear. The nonlinear
servovalve flow gain is assumed linear for ease of analysis. This method is valid and does provide
adequate servosystem gains.
Today numerous computer simulation programs exist that can easily incorporate non-linear gains.
Using a computer simulation the position control servosystem parameters can be fine tuned. The
actuator and servovalve sizing can be better evaluated and optimized. For instance it maybe
acceptable to have the servovalve flow saturate for larger step input commands. Also, a better
understanding can be obtained by varying various system parameters and observing the effect.
Control system improvements can be incorporated to observe their effect. Adjustments can be made
as required based on simulation results.






Figure 3.4 shows computer simulated results of the servosystem previously analyzed. The previously
calculated position servosystem parameters were entered into the Figure 3.1 block diagram and a
step position input applied.



Figure 3.4 Typical Simulation Response Data



4 Position Servosytem Accuracy Calculations

Servosystem Position Static Accuracy
Mechanical and electrical inaccuracies/variations will result in a slight position error in the static
condition. Generally, mechanical inaccuracies are far larger than electrical inaccuracies. The
following is a list of possible inaccuracies:
Servovalve hysteresis
Servovalve threshold
Null shifts due to temperature and supply and return pressure changes
Actuator friction
Position sensor drift
Controller amplifier draft
Blacklash (freeplay) in the system joints
Compensation for servovalve inaccuracies and actuator frictional effects should be included in the
servo loop design. This is done by ensuring the servovalve command is at least 5% of its rated
command for the maximum allowable position error in the servosystem. The 5% is considered as a
minimum, a better value would be 10% of rated current. This is one of the main reasons to ensure
the servovalve flow gain is not oversized. A large servovalve flow gain will reduce the amount of
electrical gain thereby increasing the mechanical non-linear effects.
The following relationship comes from Figure 3.1 and assumes x
command
= 0.
I = K
a
K
f
x
error
(4.1)
x
error
is the difference between the command and input. To determine the maximum position error as
a function of K
a
, re-write equation (4.1) as
I = K
a
K
f
X
max_allowable
(4.2)
where X
max_allowable
is the maximum acceptable position error. Equation (4.2) provides a relationship
between current and position error. Re-write equation (4.2) using 5% of rated current for I.
X
max_achievable
=
0.05 * I
rated _valve
K
a
* K
f
(4.3)
This will give the position error when 5% of rated current is applied to the servovalve. If it is less than
5% of the servovalves rated command you may exceed the maximum position error you desire. If it
is above 5% then the position error required should be achievable.

External Force Disturbance
If the position servosystem is static and an external load is varied the position output will vary slightly
due to the effective stiffness of the servosystem. Generally a servovalve will output full system
pressure when the servovalve signal is 2% of rated signal. That is, when the servovalve spool has
moved 2% of its rated stroke, the pressure output at one port (say C1) will be at fully supply pressure
assuming C1 is ported to a blocked chamber while the other port (C2) will be at full return pressure.
Reference the system block diagram in Figure 3.1. To generate full supply pressure we assume it
will take a command of 2% of the servovalves rated signal. Hence 0.02*I
rated_valve
yields full supply


pressure in one chamber of the actuator and full return pressure in the other chamber of the actuator.
Equating this to the maximum actuator force we get: 0.02*I
rate_valve
yields A*P
supply
, assuming a zero
return pressure. By using a ratio of the applied actuator force (F
external
) over the maximum force
output of the actuator (A*P
supply
) multiplied by 0.02*I
rated_valve
we would obtain the required current to
the servovalve to hold the applied load.
I
valve
= 0.02 * I
rated _valve
*
F
external
A* P
sup ply

(
(
(4.4)
Relating the servovalve current to actuator position error using equation (4.1) yields
X
due_to_external _ force
=
I
valve
K
a
* K
f
(4.5)
Combining equations 4.4 and 4.5 yields the position error as a function of external load.
X
due_to_external _ force
= 0.02 *
I
rated _valve
K
a
* K
f

(
(
*
F
external
A* P
sup ply

(
(
(4.6)
Thus at 2% of the valve rated current, equation (4.6) provides the position error as a function of
external load.

Servosystem Position Following Accuracy
When the commanded position to a servosystem is changing at a constant rate the servosytem
position will lag the output by a slight amount. For instance, using a position ramp command causes
the servosystem to move at a constant velocity. A finite position error signal is required in order to
generate the servovalve command necessary to produce the actuator velocity. The faster the
velocity, the more the following error, as shown by the following equations. Equation 4.5 and 4.6
provide the actuator velocity as a function of open loop gain (determined by servo parameters and
Ka) and position error.
V
actuator
=
K
a
* K
q
* K
f
A

(
(
* X
command
X
position

(
(4.7)
V
actuator
=
K
a
* K
q
* K
f
A

(
(
* X
follow
(4.8)
X
follow
=
V
actuator
K
open
(4.9)
Therefore, K
a
determines the tracking error for a ramp command. As K
a
increases, the tracking error
will be reduced.

5 Design Considerations to Improve Overall Performance



General Considerations
Some input items to consider when designing a position control system include:
Do not oversize the servovalve flow gain. When designing a servosystem the design goal
should be to put most of the control loop gain into the electronics. A position control loop can
only have so much gain before the system becomes unstable. The servovalve flow gain only
needs to be large enough to move the load at the required velocity. Servoalve mechacial
nonlinearities will tend to be minimized by incorporating most of the loop gain into the
electronics part of the loop.
Keep the servovalve as close to the actuator as possible in order to minimize the fluid volume
between the servovalve and the actuator in order to increase the actuator stiffness.
Use hard tubing between the servovalve and the actuator in order to increase the actuator
stiffness
Do not use an actuator with excessive stroke as this will decrease the actuator stiffness
Attempt to minimize the load mass the actuator has to move.
Add a DITHER signal to the command signal going to the servovalve. Dither is a sine wave
command current applied on top of the main command that goes to the servovalve. The
frequency of the dither signal is generally a low amplitude signal at the relatively high
frequency. Dither is intended to move the servovalve second stage spool at a very low
amplitude and high frequency so that that the valve spool movement will not result in a
servosystem position response. It is intended to reduce frictional effects of the servovalve
and/or actuator by keeping the servovalve spool moving all the time. Dither frequencies can
range from100 to 400 Hz.
Select an accurate position transducer. The servosystem position output can not be more
accurate than the position transducer that measures the position.
If a very high dynamic (bandwidth) servosystem is required consider using an electrical
feedback servovalve. An electrical feedback servovalve generally will have far better
dynamic response characteristics than a comparable sized mechanical feedback servovalve.

Proportional Plus Integral Control (PI)
The previous section dealt with determining the proportional gain (Ka) of the position servosystem.
An integrator can be added to the controller. Integral control is a way to reduce steady state
servosystem position error. Figure 5.1 shows how the integral gain (K
int
) is incorporated into the
basic system.
Intergal control works to reduce steady state errors since whenever the input to an integrator is not
zero the output of the integrator will keep increasing or decreasing, depending on the sign of the error
signal. When the input to an integrator is zero, the integrator output will remain the same. This
integrator characteristic can also lead to servosystem position overshoots. If a large position step
command is applied, the integrator output will build while the servosystem moves the actuator to the
correct position. By the time the actuator reaches the correct position the integral output has
increased substantially. This is called winding up the integrator. Hence the servosystem position will
overshoot the commanded position and will tend to cause the position output to oscillate. If the
position command is a ramp type of command or a smooth type of command then this problem will
not occur.
One way to prevent the integrator from winding up is to switch the integrator into the circuit only when
the servosystem position error is relatively small. Then the integrator will integrate out the remaining
error so the output exactly matches in the input.


Other compensation techniques exist but are not covered here. Many control texts present other
means of controller compensation to obtain desired stability and performance and should be sought
out for more information.



Figure 5.2 Simplified Block Diagram of a Proportional + Integral (PI) Servovalve Position Control
System