Learning System for Automation and Communications

Proportional hydraulics

Set of overhead transparencies

Basic level

D.OT-TP701-GB 095061

Order No.: Description: Designation: Edition: Graphics: Layout: Authors:

095061 PROP.H.FOLIEN D.OT-TP701-GB 8/96 T. Ocker, B. Bhland 29.7.96, M. Schwarz F. Ebel

Copyright by Festo Didactic KG, D-73734 Esslingen, 1996 All rights reserved, including translation rights. No part of this publication may be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying, or otherwise, without the prior written permission of Festo Didactic KG.

Festo Didactic

701

This set of overhead transparencies has been designed for the basic level technology package TP700. The set of overhead transparencies and the technology package form part of the Festo Didactic KG Learning System for Automation and Communiations. The 28 overhead transparencies which comprise this set have been designed in accordance with dictactic and methodological principles. Each transparency is accompanied by a short explanatory text, which gives the instructor a brief overview of of the training content covered by the transparency. Training contents:

Introduction

Fundamentals of proportional hydraulics Function and use of proportional hydraulic components Electronic components for the actuation of proportional valves Comparison with electro-hydraulic control systems

The text sheet includes a full illustration of the transparency, partly supplemented by additional explanations and designations, which can be added to the transparency by the instructor in the course of training. The advantages of this layout are:

The instructor can expand the transparencies step by step in the course of training Lessons become more interesting The available explanatory texts reduce the amount of preparation required by the instructor

701

Festo Didactic

Table of contents

Proportional hydraulic system . . . . . . . . . . . . . . . . . . . . . Transparency 1 Mobile hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 2 Proportional valve activation . . . . . . . . . . . . . . . . . . . . . . Transparency 3 Honing machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 4 Electro-hydraulics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 5 Proportional hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 6 Electro-mechanical transducers . . . . . . . . . . . . . . . . . . . Transparency 7 D.C. switching solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 8 Proportional solenoid with intermediate ring . . . . . . . . . . Transparency 9 Proportional solenoid, stroke-controlled . . . . . . . . . . . Proportional solenoid, force-controlled . . . . . . . . . . . . Proportional solenoid, components . . . . . . . . . . . . . . . Transparency 10 Transparency 11 Transparency 12

Electronic activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 13 Proportional amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 14 Ramp shaper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 15 Minimum current Maximum current . . . . . . . . . . . . . Transparency 16

Output stage ( V/I converter) . . . . . . . . . . . . . . . . . . . . . Transparency 17 Pulse duration modulation . . . . . . . . . . . . . . . . . . . . . . . Transparency 18 Hysteresis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 19 Flow characteristic curves . . . . . . . . . . . . . . . . . . . . . . . Transparency 20 Control edge patterns . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 21 Piston opening ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 22 Piston overlap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 23 Pressure relief valve, piloted . . . . . . . . . . . . . . . . . . . . . Transparency 24 Pressure regulating valve, piloted . . . . . . . . . . . . . . . . Transparency 25

Flow control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 26 4/3-way valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 27 4/3-way valve, piloted . . . . . . . . . . . . . . . . . . . . . . . . . . Transparency 28

Festo Didactic

701

Proportional hydraulics

Festo Didactic

Title Guide

Proportional hydraulic system

Classification into signal control section and power section. Signal processing has been further enhanced by the provision of setpoint value and current signal conversion. The multiple function of proportional valves reduces the number of hydraulic components to a minimum. Proportional solenoids form the interface between the signal control section and the power section.

Signal input

Signal processing, control

Actuators

Setpoint generator

Signal amplification

A p PLC

B Proportional valves

Power supply

Power supply Power section

Power section

701-01-GB

Proportional hydraulics

Festo Didactic

Title Guide

Mobile hydraulics

Origins of mobile hydraulics. Long hose connections between control valves and hydraulic drive components. Ratio of hand lever movement to piston deflection is approximately proportional. Control pattern: High-precision controllability at start of hand lever displacement, large flow rate change during hand lever movements at end deflection. In this instance, flow is not released until end deflection due to the positive piston overlap.

High-precision controllability

Piston B deflection

Flow rate [Q]

B Hand lever movement

Piston overlap A T B P A

701-02-GB

Proportional hydraulics

Festo Didactic

Title Guide

Proportional valve activation

Setpoint values are converted into magnetic flux and amplified. By means of the proportional solenoid, magnetic flux is converted into piston deflection within the hydraulic valve. Actuation of proportional directional, pressure and flow control valves.

Directional valves

Pressure valves

Proportional amplifier

Proportional solenoid

Flow control

701-03-GB

Proportional hydraulics

Festo Didactic

Title Guide

Honing machine

Typical machine tool employing a proportional hydraulic control system. Continuous path control on machine tools: Controlling of path, speed and acceleration. Smooth transition of upward and downward stroke of honing machine in accordance with time function.

Cyl. stroke advanced 1

retracted 0

Time

701-04-GB

Proportional hydraulics

Festo Didactic

Title Guide

Electro-hydraulics

Example for conventional electro-hydraulics: Control of velocity stages. Use of parallel switching flow control valve for control of velocity stages. Digital switching characteristics: only preset flow rates can be invoked (example: flow control valve). Extensive hydraulic circuit requirement.

01

23

3 2
Y4

Y3

Cylinder stroke 1 0 Time [t] Y1

Y2 Y3 1 0 0 0 1 0 1 0 1 0 0 1 0 0 0 0 0 1 1 0 0 1 0 0 0 0 0 0 Y2 Y4 M

Y1

701-05-GB

Proportional hydraulics

Festo Didactic

Title Guide

Proportional hydraulics

Example for proportional hydraulics: Control of velocity stages. Hydraulic circuit requirement considerably reduced, electrical signal control section extended. Additional requirements for commissioning: Setting of setpoint values and ramp functions. Analogue valve cross section openings according to setpoint values and thus different flow range, i.e. actuator speeds. Flexibility thanks to electrical control, e. g: an additional velocity stage requires only one additional setpoint value.

01 2

3 4

IY1
Current Time [t]

IY2
Cylinder stroke 4

IY1 Y1 Y2

IY2

2 1 0

M Y1 Y2

Time [t]

701-06-GB

Proportional hydraulics

Festo Didactic

Title Guide

Electro-mechanical transducers

Proportional solenoid: Further development of switching solenoid. The magnetic flux causes a force which remains constant throughout the stroke. The force acts only in one direction. The extent of the magnetic force is proportional to the magnetic flux. Due to its force, the servo drive of the proportional solenoid is particularly suitable for the direct actuation of standard proportional valves. Plunger coil: Also an electro-dynamic principle, whereby a force acts on a current carrying conductor in the magnetic field. Depending on the direction of current the plunger coil is deflected up or down. Torque motor: The effects of the permanent and electro magnets are superimposed. The magnetic force causes a torque to the right or the left. The servo drive, plunger coil and torque motor have a high natural frequency, which makes them suitable for the indirect actuation of highly dynamic proportional and servo valves.

F Proportional soleonid Power consumption Working stroke Linear deviation Critical frequency [W] [Nmm] (%) [Hz] 5 - 40 20 - 1000 0.5 - 6 10 - 150

x Plunger coil 0.2 - 5 8 - 80 1-7 100 - 200

x Torque motor 0.02 - 4 2 - 40 1-2 100 - 300

701-07-GB

Proportional hydraulics

Festo Didactic

Title Guide

D.C. switching solenoid

Magnetic field lines of a coil. Existence of a homogenous magnetic field within a coil without magnet core or armature. Radial air gap and axial air gap form different resistances in the magnetic field. The magnetic force acts on the armature mainly via the radial air gap, since in this case the gap between the core and armature remains small.

Radial air gap

Homogenous magnetic field

Magnetic field lines

Axial air gap

701-08-GB

Proportional hydraulics

Festo Didactic

Title Guide

Proportional solenoid with intermediate ring

Different magnetic forces act on the armature via the axial air gap. Reducing the magnetic field lines via the radial air gap by means of installing a non-magnetisable intermediate ring. The new distribution of the magnetic field line leads to a virtually constant magnetic force pattern within the working stroke range. 1 = Magnetic force characteristic in the axial air gap 2 = Magnetic force characteristic in the radial air gap 3 = Summation characteristic curve

Radial air gap Axial air gap Magnetic force [N] 6 a b c

3 2 1 a Working stroke b 1mm c Piston position

1 = Magnetic force characteristic in the axial 0 air gap 2 = Magnetic force characteristic in the radial air gap 3 = Summation characteristic curve

701-09-GB

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Proportional hydraulics

Festo Didactic

Title Guide

Proportional solenoid, stroke controlled

The solenoid force is proportional to the electrical input signal. Poppet principle: The valve cone is pressed against the valve seat via a spring; the valve opens as soon as the hydraulic force on the valve cone exceeds the pilot force, whereby the entire spring/ plunger system is moved back. Spool principle: the valve piston is pushed against the spring, the stroke movement ceases when the magnetic force and the spring force are in equilibrium. Force/stroke characteristic curves: Magnetic force with specified current values in relation to plunger position; characteristic curve of a pressure loaded spring.

Poppet principle Characteristic force/stroke curves Magnetic force [N] 6 Characteristic spring curve

Spool principle 3

0 Piston Working stroke Idle stroke position

701-10-GB

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Proportional hydraulics

Festo Didactic

Title Guide

Proportional solenoid, force controlled

The solenoid force is proportional to the electrical input signal. Only poppet type valves can be operated via force controlled solenoids. This valve is used as a pilot pressure valve for directional or pressure control valves because of the reduced flow rates.

Force/current characteristic curve Magnetic force F [N]

P T Poppet principle (only)

F~I
P

Magnetic flux I [A]

701-11-GB

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Proportional hydraulics

Festo Didactic

Title Guide

Proportional solenoid, components

Construction of proportional solenoids. D.C. solenoid group. Representation of the most important components of a proportional solenoid. Electro-mechanical transducer: the electrical input signal is converted into a mechanical output signal.

Electrical connection

Non-magnetisable inner ring Control cone

Venting screw

Core magnet

Compensating spring

Plain bearing Guide rod (stem) Housing Stop/Guide disc Barrel magnet Exciting coil Armature

701-12-GB

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Proportional hydraulics

Festo Didactic

Title Guide

Electronic activation

Control stages of a proportional amplifier for magnetic flux generation. The input signal is set by means of ramp time, minimum or maximum current and pulse duration modulation. Both the amplification of the signal and the conversion by means of a V/I converter take place during the output stage. Proportional solenoid valves are to be actuated via an adjustable D.C. current of 0 to 800 mA.

A V I

Y1

Y2

V I

Setpoint specification

Ramp setting

Setting of amplifier characteristic

Pulse-duration modulation

V/I-converter

Proportional valve

701-13-GB

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Proportional hydraulics

Festo Didactic

Title Guide

Proportional amplifier

Control panel of a setpoint and amplifier card. W1 - W8: Input of up to 8 setpoint values. R1 - R4: Setting of ramps. TIME = Ramp time. IA - IB: Setting of initial, jump and maximum current. 24V, 0V: Supply voltage. Liquid crystal display for representation of all parameters.

+24V

+24V

+24V

+24V

W1 I1

I2
R1 R2 R3 W1 W2 W3 W4 W5 TIME FUNCTION D/E OUT W8
CONTRAST

OUT

W2
IB W1 W2

I3

FUNCTION IA IA BASIC IB BASIC IA JUMP IB JUMP

R4

INT W1 INT W2

W6 W7

INT W1 IA MAX INT W2 IB MAX D/E DITHERFREQ. CONTRAST

OE A OE B

0V

0V

0V

0V

701-14-GB

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Proportional hydraulics

Festo Didactic

Title Guide

Ramp shaper

Left: Signal transmission in switching hydraulics. Right: Signal transmission in proportional hydraulics with ramp shaper. Use of ramps for adjustable acceleration or delay of hydraulic drive components. Angular setting: The ramp angle determines the adjustable speed of the valve piston. Elimination of pressure peaks and switching impacts in the hydraulic system. Displacement positions: 0: Retracted end position 1: Acceleration completed 2: Delay initiated (signal generator) 3: Forward end position
Displacement

Displacement

3
0 3

3 2
Cylinder

Signal generator
0 1 23

0 t0 t 3 Time [t]

1 0 t0 Y1 100%
Control signal

t1

t2 t3

Time [t]

Y1 t0 t1 t2 t3
Time [t]

Y2

0% Y1 1 Y1 Y2 0 t0
Time [t]

1
Input signal Signal generator

0 t0 t2
Time [t]

701-15-GB

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Proportional hydraulics

Festo Didactic

Title Guide

Minimum current Maximum current

Setting of minimum and maximum current for adjustment of proportional directional control valve to flow rate of hydraulic pump. Minimum current for adjustment of jump current to control edge. Maximum current or adjustment of maximum cross section of the opening in relation to flow rate QPump. A linear characteristic curve runs between minimum and maximum current.

[mA] I 80 0

Imax Setting

Setting I min

Amplifier characteristic

0 Setpoint value 10 Volt

Q 0

Q max.

s = min.

s = max.

701-16-GB

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Proportional hydraulics

Festo Didactic

Title Guide

Output stage (V/I converter)

The setpoint voltage is converted into a magnetic flux in the output stage. Closed-loop control of magnetic flux through comparison of setpoint value and actual value on the measuring shunt RM. The closed control loop is created by means of connecting the actual value via the feedback resistor RR. The closed control loop eliminates the effects resulting from operating voltage fluctuations and/or the effects resulting from proportional solenoid heating. The solenoid coil has an ohmic resistor RS and an inductive resistor LS.

VI Input signal R I Input resistance

VV Power supply voltage RS Coil: Ohmic resistor LS Coil: Inductive resistor Solenoid coil

RR Feedback resistor

RS LS

RM Measuring shunt

701-17-GB

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Proportional hydraulics

Festo Didactic

Title Guide

Pulse duration modulation

Recording of pulsed voltage signals and the associated magnetic flux. The output voltage is maintained at a constant level. The switch-on/ switch-off ratio (pulse duration) within a time period T influences the size of the effective magnetic flux. Clean-switching operations prevent excessive heating of the output stage and power dissipation is kept to a minimum. An oscillating output current is obtained thanks to pulse duration modulation. Sliding friction prevails at the plunger thanks to this dither effect and the hysteresis is improved.

Solenoid voltage

V 24 V

T = Duty cycle

I eff = Effective magnetising current 0 Time V 24 V T

I eff 0 Time V 24 V T I eff

0 Time

701-18-GB

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Proportional hydraulics

Festo Didactic

Title Guide

Hysteresis

The friction of the valve piston spool causes a resistance to directional movement. Hysteresis: Differential current during approach of a pressure or flow rate value from different directions. Pulse duration modulation: Reduction of hysteresis by means of continuous slight oscillating movement of the piston spool (sliding friction). Avoidance of pressure peaks in the hydraulic system.

p [bar] 50 40 30 20 Pulse duration modulation 10

100 200 300 400 500 600 700 800

I [mA]

701-19-GB

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Proportional hydraulics

Festo Didactic

Title Guide

Flow characteristic curves

Representation of control piston with different control notches; Representation of the corresponding flow characteristic curves. Delta control edge pattern: Precision controllability for small volumetric flow rates, clear changes within the range of large volumetric flow rates. The stroke travel of a piston with control notches corresponds to the maximum length of the notch opening.

Q [l/min] 8 6 4 2 0 100 400 700 I [mA]

Q [l/min] 8 6 4 2 0 100 400 700 I [mA]

701-20-GB

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Proportional hydraulics

Festo Didactic

Title Guide

Control edge patterns

Control edge pattern for the purpose of determining the flow behaviour of the valve. The adjustment of flow behaviour is linear, progressive, degressive or generally according to the task. Number of precision control openings on the periphery of the control piston depending on valve function. The sleeve system is easier to produce in terms of production technology.

701-21-GB

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Proportional hydraulics

Festo Didactic

Title Guide

Piston opening ratio

Example: Actuation of a 2:1 cylinder. The ratio of the valve flow cross sections is adjusted to the cylinder inlet and outlet by means of control edge pattern.

Cylinder 2:1

701-22-GB

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Proportional hydraulics

Festo Didactic

Title Guide

Piston overlap

Representation of positive, negative and zero overlap. Alternative designations: Overlap, underlap and zero intersection. The opening of the valve port is dependent on the notched opening in relation to the control edge. The flow rate is also adjusted by means of the throttle opening ratio of the control piston. The number of radially configured notches on the control piston.

QA positive QB QA zero QB QA negative QB

QL

X >0

QL

X =0 QL

X <0

701-23-GB

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Proportional hydraulics

Festo Didactic

Title Guide

Pressure relief valve, piloted

Sectional view of a pressure relief valve. The mode of operation corresponds to that of a conventional, piloted pressure relief valve. Piloted stage: the force set for the proportional solenoid is transferred to the pilot poppet via the spring. As soon as the pressure acting on the pilot valve exceeds the value set, the poppet valve opens. The venting control flow generates a pressure drop at the main stage, whereby this opens.

p [bar] 5 4 3 2 1
TY

P 0 20 40 I [mA]

701-24-GB

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Proportional hydraulics

Festo Didactic

Title Guide

Pressure regulating valve, piloted

Sectional view of a piloted pressure regulating valve. Reduction of system pressure to a specific value. Application for subranges within a hydraulic system.

P A
PY

701-25-GB

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Proportional hydraulics

Festo Didactic

Title Guide

Flow control valve

Sectional view of a flow control valve. Normal position: all ports are closed. Depending on the piston deflection, control cross sections (holes in the piston, control sleeve) and thus the flow are changed.

AB

PT

Q l [ ] min 8 6 4 2

Flow characteristic curve

100 200 300 400 500 600 I [mA]

701-26-GB

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Proportional hydraulics

Festo Didactic

Title Guide

4/3-way valve

Essential functional components: Proportional solenoids, main spool, reset spring. Multiple functions: Directional control, speed control, hydraulic clamping of power components (throttle opening ratio).

AB

PT

T B P A

701-27-GB

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Proportional hydraulics

Festo Didactic

Title Guide

4/3-way valve, piloted

Pressure relief valves for pilot control of a 4/3 proportional directional control valve. Electrical signal to one of the two proportional solenoids increases the pressure inside the control chamber of the main spool to a specified value (relief pressure). The control piston is moved up to the equilibrium position with the opposing spring action. High control force due to minimum control pressure of 25 bar eliminates sensitivity to disturbance factors. This is however associated with continuous control oil consumption. Without an electrical signal, the control piston is centred by means of the springs.

AB

PT

P T

P T

Actuation B

Actuation A

701-28-GB