Atos spa

Table F002-3/E

21018 Sesto Calende, Italy - Fax 0331 920005

Basics for updated electrohydraulic axis

a due stadi, pilotate, dimensioni ISO/Cetop 07 e 08
1

MOTIONS IN MODERN MACHINES ARE MADE BY CLOSED-LOOP AXIS

The motion control of modern machines is substantially a problem of axis control. Today industrial machines are multi-axis machines, more and more electrohydraulically controlled by proportional devices.
The control of an electrohydraulic axis should always be in closed loop. Only a closed-loop system takes full benefit from joining
electronics to hydraulics: precision, response time, repeatability, indipendence from enviromental disturbances. Moreover, a closed loop control rationalizes complex systems: one only processing unit can drive different cards and many different axis. The
scope of this technical table is to summarize the basics for a modern control of an axis.
See table F001 for generalities on control loops and proportional electrohydraulics.
2

WHY STANDARD COMPONENTS

Closed loop controls for modern systems should be realized using standard hydraulic and electronic components.
With standard components you have the following advantages:
- a rationalization of your machine;
- a cost effective solution;
- the use of easily interchangeable components, proportional valves and ISO cylinders with standard attachments (hydraulic and
electric) means easier start-up and service plus possible changes of use for possible revamping.
Leading manufacturers follow the same international standards.
3

TYPICAL ELECTROHYDRAULIC SCHEME

A basic and common block diagram is on Fig. 1.

Reference is made to linear servoactuators. Servomotors and rotary servoactuators follow the same concepts.
The basic scheme can be fit with safety valves,counterpressure valves, load sensing systems and auxiliary valves.
Atos Technology Dept. may cooperate to suggest the best machine-tailored solution if complete information on application are
duly supplied.

FEEDBACK

CENTRAL
PROCESSING
Axes
Controller UNIT

DRIVER
REFERENCE
SIGNAL

Fig 1: Electrohydraulic axes: a basic block diagram

1
2
3
4

=
=
=
=

ACTUATOR
PROPORTIONAL VALVES AND DRIVERS
ELECTRONIC CONTROLLER
POWER UNIT

ACTUATORS AND TRANSDUCERS

Electrohydraulic motions are resolved by linear or rotative actuators. The former are monitored by analog or digital position transducers that supply the position feedback to close the loop and may be directly mounted on the actuator (built-in transducer).
Usually the servocylinders are equipped with integral proportional valves on hydraulic manifold blocks to increase the stiffness of
the system (see section  of this table)
Atos servocylinders are in low friction execution with high static and dynamic characteristics to improve the control performances.
Atos line offers:
- servocylinder type CKP, CCP with built-in potentiometer transducer: the cheapest and most commonly used.
- servocylinder type CKW, CCW with built-in inductive transducer (Fig. 2): contactless, preferred in case of high speeds
and/or working frequencies, or with an exasperate duty cycle.
- servocylinder type CKM (F), CCM (F) with built-in magnetosonic transducer (analogic) (Fig. 2): when high positioning
accuracy or accurate velocity control is required.
- servocylinder without built-in transducer: in this case the transducer has to be placed outside the cylinder to feedback the
position from the last actuated machine. Typically they are inductive transducers and linear or rotative encoders (with pinion and
rack).
See table B310 for standard cylinders (section ) with or without built-in subplates (section 11 ) and for transducer characteristics
(section ).
Rotative actuators are commonly suited with digital encoders or analog dynamos rispectively for position/speed and speed controls.

F002

Permanent magnet
(moves with piston)
Ferromagnetic wave guide
(integral with cylinder body)
Demodulator
Stainless steel
protective tube

Primary
Core
Secondary

Secondary

Pulse
generator
& receiver

Cylinder rod

Oscillator

Application

Fig 2: Inductive (A) and magnetosonic (B) linear transducer

Piston

The force/pressure closed loop controls are processed according to the same procedure of position and velocity controls, but
using pressure transducers or load cells.
The ZO-TER versions on proportional pressure control valves are equipped with integral pressure transducer and electronics,
which provide pressure closed-loop control.
Pressure controls may be direct operated (see tables F007, F015) or pilot operated (see tables F035, F040)
5

PROPORTIONAL VALVES AND DRIVERS

High performance proportional valves compare with good servovalves whilst maintaining the typical benefits of proportional
hydraulics: less sensitivity, coarser filtration requirements, intrinsic stability, low hysteresis.
Atos proportional valves and relative drivers are marked CE according to the EMC and Low Voltage Directives.
For complete information about proportional valves and controls see specific technical tables.
Single solenoid valves are the right choice for running a closed loop system, by making the control easier and cost effective.
While selecting the proper proportional valve, consider:
- select spool with zero overlapping (for instance valve type DLHZO, table F180);
- choose a valve with a frequency response characteristic of at least 30 Hz at 90 phase shift (Bode diagram);
- choose the proper fail-safe configuration (Fig. 3) to prevent from damages in case of electric breakdown;
- use a linear spool for position controls (/L version in the code);
- repeatibility and hysteresis 0.2%.
The recommended execution is the version TE with integral electronics, factory preset: it ensures fine functionality plus valve-tovalve interchangeability and symplifies installation wiring and set-up.

*40-L*3

*60

For better operation of a closed loop, select spools with max flow rate 1025%
more than max regulated flow (better control of minimum flow rate and of hydraulic
gains).
When high translational speeds and accurate approachs are combined, use the
breaked regulation of series T valves and relative drivers (see table F190).
Select the proper fail-safe configuration (Fig. 3) according to the axis safety requirements, in case of electric black-out.

*40-L*1
Fig. 3: Fail-safe configurations.

Fig. 4: DPZO-LE-270*

Valve type DPZO-LE with double feedback transducer (on the main and pilot
spool) are available too (Fig. 4). They are used to obtain higher precision and
improve static and dynamic performances. In this case Atos integral electronics
controls two feedback signals in double closed loop.

Valve type LIQZO-LE (see tables F330, F340) with double feedback transducer
(on the main cartridge and pilot spool) are available too (fig. 5).
They are 2-way or 3-way and thanks to a double-active piloting system they can
improve flow and dynamic performances of injectjon plastic, ceramic, punching
machines.

Fig. 5: LIQZO-LE

For high flow rate, proportional cartridge valves are available too (see tables F300, F320). They are standard elements for manifold
mounting resulting in compact and cost effective solutions.
Any proportional valve is fed through an electronic driver supplying a modulated current to the solenoid proportionally to the reference signal. To assure the best operation the driver should be supplied by the manufacturer of the valve.
The reference signal is normally in tension (Volt); alternatively it may be in current (Ampere), the latter used when great lengths
apply to reference and feedback connections, causing interferences and electrical noise.
In any case pay attention to shield the electrical cables with shield or cablebraid connected to the ground.
The driver may be integral with the valve (AE, TE, LE versions) or separated (Undecal and Eurocard formats).
Digital cards are also available; they support advanced algorithms and solutions and assure a more precise behaviour. These drivers should be used only for machines manufactured in great numbers where joining digital control and software optimization, provided by the customer, results in a cost effective solution.
For detailed information on drivers, see technical tables on section G.

ELECTRONIC CONTROL SYSTEM

The electronic control system includes a control unit and

one or more axes cards. It is usually up to the customer
the choose of the machine control system.
Firms without a skilled electronic section should collaborate with a system integrator to select the best standard
hardware and develop a customized software.

PERIPHERICS
Data
Memory

Monitor, keyboard
Registrator
Printer

I/O
INTERFACES

CPU
Program
Memory

PROCESS
Digital-analog inputs
Digital-analog outputs

Fig. 6: Block diagram of a control unit

The machine control unit includes a data processing unit (PLC, PIC, CNC) to elaborate the Input/Output signals (Fig. 6).
This data processing unit is equipped with a terminal board to input the programming data and it is fitted with dedicated peripheral units, i.e. axis cards and other electronic controllers for coordination of various axes.
The electrohydraulic control system can be optimized on both hydraulics and electronics side with the collaboration of Atos
Technology Department according to detailed application analysis.
The axes card is the interface between the control processing unit (which processes the main user programme) and the electrohydraulic systems, to which the reference signals are driven.
Axes cards may be analogic or digital, the latter the most spread. Digital axes are directly interfaceable with linear and rotative
encoders and magnetosonic transducers and easily with inductive ones, by means of proper auxiliary cards. To interface an analog transducer with an axes card, an A/D converter must be provided. It will have a resolution of 12 bit at least for good performances.
Essentially, an axes card compares reference and feed-back signals and performs the computing of the output control signal.
The most common controller is the PID type where adjustable parameters are:
P: proportional to the error; I: proportional to the steady state error; D: proportional to the rate of change of the error.
An axis card can control one or more axes (up to six, even synchronized) and can be for standard applications or for specific
high performances, sometimes with high level languages.
Several manufacturers offer advanced axes controllers and regulation cards: SIEMENS, OMRON, ALLEN BRADLEY, TELEMECANIQUE, etc. Atos can supply the analog E-ME-K-PID electronic controller, designed to easily control position, or speed or pressure in simple closed-loop systems.
7

CLOSED LOOP SYSTEM ANALYSIS

This section is designed to provide a basic and practical approach to performance estimation of closed-loop systems.
The basic concepts described in the following are nowdays integrated with the tools of advanced simulation programmes. With
them its possible to build up complex circuits connecting the different functional blocks to represent the loop, after determining
every elements output characteristics. Further, its possible to simulate the behaviour of complex systems and to analize their
dynamic response: in particular its easy to develop parametric studies (varing stiffness, mass, type and size of proportional valves).
The electrohydraulic applications may be essentially devided into:
- dynamic applications: movement of loads at high
speed/frequency;
- force applications: to transmit high forces at low speed.
The problems arising in dynamic applications are of difficult evaluation but of great importance. Most malfunctioning derive from neglecting a frequency approach to the
system.
Two aspects are to be considered:
- hydraulic stiffness of the system;
- inertia of the loads.
In many applications, hydraulic fluid is considered to be
incompressible. This is not absolutely correct, since when
pressurized, a fluid will compress in much the same way
as a spring (Fig. 7). In fast-acting servo systems with high
dynamic loads even piping may be seen as elastic, above
all for high values of pressure. Attention should be paid to
the presence of accumulators: they better performances
but make the system more critical from the dynamic point
of view.

Fig. 7: Actuator as a spring/mass system

Input

Output

Transfer function
Fig. 8: Block diagram: transfer function

A closed loop control system analysis can be simplified by

regarding components (or set of components) as blocks
(Fig.8). The relationship between the input and output of a
single block is the gain (G).
The system loop gain Kv (fig. 9) can be got summing the
gains of the single blocks of the loop (amplifier GD, pro-

Summing Junction

portional valve GV, cylinder GC, feedback). The higher the

system loop gain, the better overall performances.
However, an excessive gain may cause the system to go
unstable (Fig. 10).
In this situation the overshoots and undershoots diverge.
The maximun value of the gain that can be used to assure
system stability is determined by:
- the load mass (M); the larger the mass, the greater the
inertia forces, the greater the tendency to oscillate.

Input

Error
Feedback

KV = GD x GV x GC

Fig. 9: System loop gain

F002

5
0.
>

3
0.

KV > 0.2 S

the minimun among:

- V: natural frequency of the valve (assumed to be the frequency at 90
phase shift; see tables F160, F170, F180);
- = CH/M: natural frequency of the mechanical system (generally 10

>

Speed

- the stiffness of the actuator (CH); low stiffness means high tendency to
oscillate, so the stiffness should be as high as possible;
- the damping coefficient () of the system (tipically = 0.05 0.3). This
parameter is influenced by the characteristic of the valve (non linear characteristics, etc.).
To ensure the system stability:
KV 2 S
where S, the natural frequency of the complete closed loop system, is

Increasing
Gain

Time
Fig. 10: Answer to a step signal increasing gain

100 Hz; see fig. 11);

- : natural frequency of amplifier and feedback transducer (usually
ignored, because at least ten times higher than V, ).
In industrial applications of electrohydraulic axes the critical frequency is
always .
For linear actuators is calculated with the following formula:



40 EA1

1+

rad

cM

sec

Hydraulic
Stiffness of
actuator (CH)

E = 1.4 107 Kg/cm.sec2 (oil elastic modulus)

c = stroke (mm)
M = mass (kg)
A1 = piston area (cm2)
A2 = anulus area (cm2)
= A2/A1 = anular/piston cross section ratio

The natural frequency for a cylinder-mass system is directly related to

the minimum acceleration/deceleration time permissible to maintain the
functional stability (Route-Hurwitz criterium).

Load

= 2fo
Fig. 11: The mass/spring mechanism.

tmin = 35/ (s)

Experience has shown that if the calculated minimum ramp time tmin to
assure stability in a system exceeds approximately 0.1 seconds, the
system should be re-examined.
Once fixed the total cycle time and stroke, it is possible to obtain the maximum speed:
Vmax = Stot / (ttot tmin)

Stot = total stroke (mm) ttot = total cycle time (s)

Vmax

amax = Vmax / tmin

Overall stiffness is important even to determine the static performance in
terms of how accurately the electrohydraulic axis achieves and maintains a
demand position, being more reactive to possible external disturbances:
reactive loads on actuators (tool forces, shock loads), load weight (vertically mounted cylinders), friction on slides, gap at joint.
Further parameters to strictly monitor are: valve null shift due to temperature or pressure variations, accuracy or resolution of feedback transducer.

Amax

tmin

tmin
ttot

= 69.12 rad/sec
tmin = 0.51 sec

M = 2000 kg

CLOSED LOOP SYSTEM ANALYSIS: AN EXAMPLE

The following example shows the great influence of the dynamic characteristics in a closed-loop system.
Consider the simple sketch in Fig. 13. The cylinder is connected to a proportional valve; the machine cycle dictates that the cylinder must complete
its forward stroke in a time of 2 sec.
Using the relations of section , we get:

= 25 mm

Vmax = 0.67 m/sec

A1 = 19.6 cm2
A2 = 14.7 cm2
= 0.75

amax = 1.31 m/sec

Finertia = M xa = 2620N
Pmin = (Finertia + Fload)/A1 = (2620 +19620)/19.6 [

Valve

Qmax = Vmax x A1 = 0.67 x 19.6 x 60/10 = 78.9 l/min

N ] = 113.5 bar
] = 1.135 [cm.

N
cm.2

Prequired = pmin + pnom.valve +pcircuit-drops = 113.5 + 70 +16 = 199.5 bar

Prequired is the value of pressure supplied by the power unit.

Select a proportional valve with a pnom.valve in the range shown in the technical tables. In the previous example you may choose a DLKZO-TE-040L71 valve (Q = 90l/min, pnom.valve = 70 bar).
The above calculations determine the needed pressure to perform the
cycle with the required dynamics.

10/01

t
Time

Fig. 12: Positioning cycle

c = 1000 mm

Speed

and consequently the maximum acceleration

50 mm

Fig. 13: The system analysed on the example.