TM480 Hydraulic Drive Control

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Hydraulic Drive Control
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Requirements
Training modules: TM210 – The Basics of Automation Studio
TM211 - Automation Studio Online Communication
TM213 – Automation Runtime

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TM223 – Automation Studio Diagnostics
TM400 – The Basics of Motion Control
Software: AR 2.80 and higher
Hardware: SG4
2 TM480 Hydraulic Drive Control

Table of contents
1. INTRODUCTION 5
1.1 Objectives 6
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1.2 A hydraulic task 7
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2. BASICS 9
2.1 Basic laws of hydrostatics 9
2.2 Hydrostatic pressure: The effects of gravity 10
2.3 Flowing fluids 11
2.4 Comparison between electrical engineering and
hydraulics 14
3.1 Tank
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3. HYDRAULIC DRIVE SYSTEM STRUCTURE
3.2 Displacement devices: Pumps and motors

3.3 Valves
3.4 Pipe layout
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15
16
20
25
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3.5 Accumulators 26
3.6 Working fluids 26
3.7 Sensors 27
4. HYDRAULIC DRIVES AS CONTROL SYSTEMS 29

4.1 Pump-controlled system 29
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4.2 Valve controlled system 30
5. CLOSED LOOP CONTROL CONCEPT 33

5.1 Hardware configuration 33
5.2 Closed loop control strategies using the AsHydCon
library 34
6. AXIS COUPLINGS 55
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6.1 Application solution 55

6.2 Connecting to ACOPOS 55
6.3 Connecting to ARNC0 56
6.4 Exact synchronization 57
7. SAFETY 58
7.1 Safety concept 58
7.2 Limitations and prohibited operating areas 59
Hydraulic Drive Control TM480 3

7.3 Integrating the SafePLC 61
7.4 Testing the implemented safety functions 61
8. SUMMARY 62
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9. APPENDIX 63
9.1 Solution guide 63
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9.2 Commissioning 75
9.3 Controller settings 76
9.4 Controller optimization 77
9.5 Further literature 78
9.6 Overview of AsHydCon library function blocks 79
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Introduction
1. INTRODUCTION
Hydraulics involve the transfer of energy and signals using fluids. In this
training module, we will be taking a closer look at hydraulic drive
technology, with a special emphasis on the area of hydrostatic drive
technology.
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This generally involves creating mechanical movements. The hydraulic
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system almost always has the job of a gearbox, because it uses the power
of a motor (electro or diesel motor) and converts it to a mechanical
movement of a hydraulic actuator (cylinder or hydro motor), see also
Figure 1.
Hydraulic system
Mechanical Mechanical
energy
(motor)
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Hydraulic energy (fluid)
energy
(piston rod)
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Figure 1: Hydraulic drive system structure
About the training module structure:
We will begin by introducing a type of task that occurs frequently in

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hydraulic drive technology. Throughout the training module, we will learn

how to create solutions for this type of task.
We will start by looking at a few basic principles of hydraulics as a way of

presenting some of the main standard components in a hydraulic circuit,
such as hydraulic tanks, pumps and motors, as well as linear drives, valves
and piping because all hydraulic systems consist mostly of these elements.
We will then introduce the basics and main concept of hydraulic drive
closed loop control and the use of the software tools provided in the B&R
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AsHydCon library.
This information will be used to solve the task presented at the beginning
step by step.
Material for more advanced tasks and exercises is provided in the

appendix.

Introduction
1.1 Objectives
The goal of this training module is to impart a fundamental understanding
of the interrelationships in hydraulics, to learn about hydraulic tasks, also
with the use of circuit diagrams, and to evaluate and to solve hydraulic
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closed loop control tasks with the help of the B&R hydraulics library,
AsHydCon.
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You will get to know the basic (linear and non-linear) closed loop control
methods for hydraulic drives and how these are appropriately implemented
using Automation Studio and the AsHydCon function blocks.
Another main goal of this training module is the selection of the right
hardware for the respective application.
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All of this knowledge will be discussed and applied in a practical task, so
that at the end of the training module you will be able to solve the tasks
presented as well as similar standard hydraulic applications and will have
the knowledge needed to work out more advanced tasks on your own.
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Figure 2 Overview

Introduction
1.2 A hydraulic task

A standard application in hydraulics is the position control of one (or more)
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hydraulic cylinder(s). The closed-loop control task is to control a
hydraulically-driven axis in such a manner so that it follows a position
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setting.
For many applications however, this just isn't sufficient. The ability to
generate a precisely-defined force with the hydraulically-driven axis is still
desired. Force control mode and the ability to switch between these two
operating modes without jolt is needed to do this.
Application examples which switch from one of these operating modes to
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the other include all types of presses, as well as closing mechanisms such
as those in injection molding machines. Figure 3 shows a photo of a
granulate molding press.
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Figure 3: Granulate molding press
A rough hydraulic diagram for this sort of system is illustrated in Figure 4.

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Figure 4: Rough hydraulic diagram for cylinder control

Introduction
Task definition:
In an initial step, a position controller should be developed for a system
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with the hydraulic diagram shown in Figure 4 so that the cylinder piston
follows a cyclic movement profile between two freely definable end
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positions. When doing this, be sure to achieve the highest possible level
of control quality by integrating additional measurement signals.
In a second step, a change from position control to force control should

take place at the positive end position, whereby at this end position a
definable set force must be kept constant for a definable amount of time
before a force reduction occurs and is then switched back to position
control.
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Basics
2. BASICS
The aim for hydraulic systems, as covered in this training module, is to
utilize the laws of hydraulics (more specifically, hydrostatics) to implement
a desired function.
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This is why we will be discussing some of the fundamental interrelations of
hydraulics in the following section.
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2.1 Basic laws of hydrostatics
The basic law of hydrostatics assumes an ideal massless, frictionless and
incompressible fluid. Pascal's Principle is valid for such fluids:
The affect of a force on a stationary fluid propagates in all directions
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within a fluid. The amount of pressure in the fluid is equal to the load
force, based on its effective surface. The pressure is always applied
vertically to the contact surface of the container.
The hydrostatic press is an example of a simple application, see also Figure

5.
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F2
F1
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s1
p
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Figure 5: Hydrostatic press

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The pressure p is represented as force per surface, therefore
F1 F2
p= =
A1 A2

Basics
These are now the measurement units used for the pressure p , which is
now almost the same throughout the container:
1 Pa (Pascal) 1 mN2
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1 bar 105 N
m2
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1 psi (pound per
0.0703 bar = 7030 Pa
square inch)
kp
1 0.981 bar
cm 2
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The lever law of hydrostatics follows from this interrelation, which states
that a small amount of force F1 can be used to generate a large amount of
force F2 , if the surface A2 is inversely proportionally larger than the surface
A1 .
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2.2 Hydrostatic pressure: The effects of gravity
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∆h
Figure 6: Pressure distribution in a cup of coffee

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The pressure in a container is not constant throughout its depth because

fluids are generally not massless. For example hydraulic oil has a density of
kg
approximately ρ = 900 3 .
m

Basics
In fact, depending on the depth ∆h , the pressure in the container increases

in the form
∆ p = ρ g ∆h .
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m
Here g = 9.81 indicates gravitational acceleration.
s2
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2.3 Flowing fluids
In a stationary fluid, the pressure increases with depth. Points at the same
depth have the same pressure.
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However, a drop in pressure occurs when fluid flows through a pipe.
Similar to electrical engineering, by which an electrical current I causes a
drop in voltage ∆U on an electrical resistance R , as represented by the
following equation
∆U = R ⋅ I ,
in hydraulics, a flowing fluid leads to a pressure drop along the flow, see
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Figure 7.
∆U=U1-U2 ∆p=p1-p2
I Q
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p1 p2
U1 R U2
Figure 7: Electrical and hydraulic resistance
However, there are two main differences:

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Basics
2.3.1 Flow in narrow gaps and pipes:
Pipe wall
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p1 Q DH p2
Figure 8: Laminar pipe flow with speed profile
∆p = RH Q.
with the flow rate Q (e.g. in l

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If the flow rate in a pipe is low enough, then the loss of pressure is linearly
dependent on the flow rate,
) and a resistance value. In this case of

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min
the laminar pipe flow, resistance coefficient RH depends on the diameter
and length of the pipe and on the viscosity of the fluid. However, laminar
pipe flow becomes instable as the flow rate rises. If the Reynold's number
is
v⋅D⋅ρ
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Re = > 2300,
η
with the dynamic viscosity of the fluid η , the fluid speed v and the
hydraulic diameter DH (see Figure 8), then the laminar pipe flow changes
to turbulent pipe flow. In this case, the relationship between the flow rate
and pressure drop is squared, whereby the following equation applies:
∆p
∆p = K H Q 2 or Q=
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KH
Usually, pipes in hydraulic systems are designed to promote laminar

flowing, which considerably reduces pressure drop and flow noise.

Basics
2.3.2 Flow through (sharp edged) orifices:

Orifices produce a square-root relationship between the flow rate through
the orifice and the pressure difference. This is also decisive for controlling
hydraulic systems because hydraulic valves mainly function on this
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principle. For an orifice holds
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∆p
∆p = K H Q 2 or Q=
KH
with a constant K H , which depends on the geometry and characteristics of

the orifice. Once again, K H is larger, the smaller and sharper-edged the
opening of the orifice is designed.
p1
Orifice
Q ep
Pipe wall
p2
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Figure 9: Flow through an orifice
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It is important that the pressure loss coefficient K H in this case is not

dependent on the viscosity of the oil (and therefore the influence of
temperature). The independence of this coefficient from the operating
temperature is the reason for implementing hydraulic valves using orifices.
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Basics
2.4 Comparison between electrical engineering and hydraulics

The following Table 1 illustrates the relationship between hydraulic values
and corresponding electrical values.
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Electrical Hydraulics
U [V ] p [bar ]
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Voltage Pressure
Current I [ A] Flow rate Ql 

 min 
Electr. Linear, Hydraulic Linear,

resistance non-linear resistance non-linear
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Table 1: Comparison of electrical and hydraulic values
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Hydraulic drive system structure
3. HYDRAULIC DRIVE SYSTEM STRUCTURE

An (open) hydraulic drive system generally consists of the following
components:
• System pressure pump: Driven by an electric motor, this pump's
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job is to provide the hydraulic energy. Mechanical energy is
converted into hydraulic energy here.
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• Tank: With open hydraulic circulation, the working fluid flows
from a tank through the pump, to the actuators and back to the
tank via supply lines.
• Pipes, hoses: They transfer the hydraulic medium (hydraulic oil)
from the system pressure pump to the valves, to the actuators
and back to the tank.
• Valves: Used to control the flow of hydraulic fluid. There are
•
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different types of valves, such as switching valves (which have a
finite number of switching positions) and continuous valves
(which have an infinite number of switching positions and can
therefore be used for variable resistance).
Actuator: The actuator is either a hydraulic cylinder (linear motor)
or a (rotary) motor. In the actuator, a majority of the hydraulic
energy is converted back to mechanical energy.
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• Sensors: Position, pressure, flow rate and force sensors.
• Other components: Pressure relief valves (limits the pressure in
the hydraulic circuit to a definable value), filter (filters particles
from the pressure fluid), heat exchanger (cools the pressure fluid),
etc.
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The components listed here can also be found in the hydraulic diagram in
Figure 4.
In the following sections we will take a closer look at the most important
components of a hydraulic circuit.
3.1 Tank
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The two main types are hydraulic systems with closed circulation, in which
the flow returning from the actuator is fed right back into the pump, and
systems with open circulation.
With open circulation, the working fluid flows from a tank through the
pump, to the actuators and back to the tank via supply lines. The tank's
volume is measured in a way that results in a specific working fluid dwell
time in the tank for the defined flow rate of the pump. This dwell time is
used to

• separate air bubbles in the pressure fluid,

• separate dirt particles that got in the working fluid through
assembly, wear and tear, cutting production of components, or
other reasons,
• separate water if oil is used as working fluid (lubrication and
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protection against corrosion),
• dissipate heat via the tank surface if a separate cooler is not being
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used.
Figure 10 shows the symbol for the hydraulic tank.
Figure 10: Hydraulic tank symbol
3.2 Displacement devices: Pumps and motors

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Pumps are used for converting mechanical energy to hydraulic energy
(especially in hydrostatics). Motors handle inversion. These are divided
into linear and rotary motors. Figure 11 contains a few switching symbols.
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Figure 11: Displacement device symbols
Symbol (a) represents a fixed displacement pump for one direction of

rotation, (b) a variable displacement pump for two directions of rotation. (c)
represents a linear drive (double acting differential cylinder).

3.2.1 Rotary units

Most displacement machines can be used as either motor or pump
because the hydrostatic displacement process is reversible. In actual usage
however, pumps and motors are often designed differently and optimized
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for their respective application.
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Maximum speed, displacement volume Vs and maximum differential
pressure as well as efficiency are significant characteristics for a pump or
rotary motor. These characteristics are also decisive for the use of the
motor. Of course, the construction also plays a role in its application.
The displacement volume Vs is defined as
Q [ l min ]
Vs [ l U ] =
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n [U min ]
with the flow rate Q and the speed n . This value can be changed on axial
motors or pumps, but is a constant on fixed displacement pumps.
Therefore a hydro motor's speed can be altered either by changing the

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supplied volume, or by adjusting the motor's displacement volume.
Alternately, the flow rate of a pump can be changed by changing the drive
speed and the displacement volume.
Variable displacement pumps are often used for both rotary pumps as well
as rotary motors in industrial applications. These are further subdivided
into wobble-plate, swash-plate and bent-axis machines. Of these variations,
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swash-plate machines have the most significance because they are highly
robust and can be manufactured inexpensively.
Figure 12 shows the cross-section of a swash-plate pump. In this pump, the

cylinder block (1) is driven. The pistons (2) inside the block are then also
put into motion. They are fastened via the piston shoe (4) to the swash-
plate (3) mounted in the housing, which can be tilted by an activator piston.
The pistons also move in the axial direction when rotated. When the
pistons move to the left, they suck the fluid into the resulting vacuum
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section from the connected line and push the fluid back out when moved to
the left. This is referred to as the pump's suction and pressure phase. The
stationary valve plate (5) switches the connected lines between suction and
pressure phase.

The swash-plate pump is the most common axial piston pump because it is
easy to adjust and is highly robust.
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Figure 12: Cross section of a swash-plate pump
Radial piston machines are also subject to the piston principle. In these
machines, the piston axis and drive axis are positioned perpendicular to
one another. The cylinders form a star shape around the drive axis.
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Other displacement principles are also used in pump and motor designs.
These include the gear principle (gear pumps/motors, annular gear
pump/motors, screw pumps) or the vane principle (vane pumps/motors,
rigid vane and rolling vane machines).
Pulsation of the displacement flow rate usually occurs in all displacement

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devices during pump operation. Inversely, the output speed and output
torque usually pulsate during motor operation. However, this effect is
reduced at higher speeds because of the effects of inertia.
3.2.2 Hydraulic cylinders (linear motors)

Just as with rotary motors, hydraulic cylinders also convert hydraulic
energy back to mechanical energy. Due to their simple structure, hydraulic
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cylinders are highly robust and cost-effective actuators for linear

movements.
The crucial aspect when manufacturing cylinders is the coating of the

piston rods and the design of the seals. These two elements are decisive
for airtight and wear-resistant operation at lower frictional forces.

Single-acting and double-acting cylinders are the two main types. Double-
acting cylinders can be either synchronizing cylinders (both piston areas
are the same) or differential cylinders (the piston areas are different).
Double-acting differential cylinders have a preferred direction of
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movement, in which higher forces can be generated due to the different
piston areas Apos and Aneg , see Figure 13. This is usually defined as the
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"positive" direction of movement. Therefore, the piston moves faster when
performing movements to the right.
scyl
Apos Aneg
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A B
Valve fittings
Figure 13: Hydraulic cylinder (differential cylinder)

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This asymmetry (different system gains for movement in the positive or

negative direction) must be taken into consideration when controlling a
hydraulic cylinder in order to achieve an equally dynamic behavior in both
directions of movement.
Cylinders are often designed with end position damping. Keep in mind that
these damping elements are designed for cylinder delay without external
load. These types of damping cannot be used to decelerate moving loads.
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A suitable (position) controller must be used to do this.

3.3 Valves
According to DIN/ISO 1219 valves are:
"… devices for the open or closed loop control of start, stop and direction
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as well as pressure or flow (flow rate) of the pressure medium delivered by
a hydraulic pump or stored in a container".
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Valves vary based on:
• Design (slide, rotary slide or seat type),
• Control (manually operated, electrical, hydraulic, pneumatic, etc.),
• Action (continuous, switching)
these characteristics, e.g.
•
Determining direction ep
Valves can implement different functions depending on the combination of
Controlling pressure (pressure-regulating valves, pressure-relief

valves)
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• Controlling flow rate
• Blocking, etc.
3.3.1 Symbols
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(a) and (b) in the following Figure 14 indicate the basic symbols for a 2-way
switching valve and a 2-way proportional valve. A 4/2-way switching valve
is represented by (c) and a 4/3-way proportional valve by (d). The first
number indicates the number of connections. The second number specifies
the number of valve positions.
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Figure 14: Symbols for different direction control valves

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Figure 15: Symbols for other valves:
(a) check valve, (b) pressure relief valve and (c) pressure reducing valve
3.3.2 Switching valves
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Switching valves are direction control valves with fixed switching positions
and therefore non-continuous elements.
3.3.3 Continuous valves: Proportional and servo valves

The opening of continuous valves can be changed continuously. This
means they allow an exact amount of flow rate through the valve to be
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defined as well as the direction.
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Figure 16: Cross-section of a 4/3-way servo valve
Figure 16 illustrates the cross-section of a two-stage 4/3-way servo valve.

In a multi-stage valve, the control signal (usually a voltage value in the

range -10 V .. +10 V) for the valve does not directly induce movement of
the spool and therefore a change of the flow rate through the valve. In fact,
one or more power stages reinforce this signal in such a manner so that a
quick movement of the spool, and therefore a quick change in the flow rate
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through the valve, are possible. Servo valves, which are used as
particularly high-speed actuators, always have a multi-stage design.
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The valve connections are labeled P for high pressure, T for low pressure
(tank), A and B for the lines to and from the actuator (i.e. to the pressure
chambers of a hydraulic cylinder). X indicates the connection for a control
pressure line. It is used here to provide the pressure needed for the
hydraulic piloting-stage in the valve, based on the nozzle-flapper principle.
Y indicates an leakage oil line, which is also usually connected to the tank.
Figure 17 is a detailed view of the control slider in a 4/3-way valve like the
one illustrated in Figure 16.
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T A P B T
Figure 17: 4/3-way longitudinal slide valve. Control slider set for negative direction
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QA QB
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System
pressure
pSys pT
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Figure 18: Interconnection between continuous valve and hydraulic cylinder

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Continuous valves are characterized using two characteristic curves. Due to
their structure, they have the same flow rate - pressure dependency when
opened a certain amount, as orifices have. Usually, they are described by
specifying a nominal flow rate for connection A and B, Qnom , A or Qnom ,B , at
nominal pressure difference (usually ∆pnom = 5bar or ∆pnom = 35bar ) and
maximum valve opening y = 1 . This makes it possible to specify flow rate /
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pressure relationships, e.g. for positive valve displacement y, for

continuous valves for the connections A and B in the form
Qnom, A Qnom ,B
QA = y pSys − p A and QB = − y pB − pT
∆pnom ∆pnom
with the pressure drop on the valve ∆p and the flow rate on the
corresponding connection Q A or QB . The negative sign in QB means that
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the flow rate runs out of the chamber instead of into the chamber as
indicated in Figure 18. To adapt the flow rates of both connections A and B
to asymmetric actuators such as differential cylinders (see Figure 18),
valves are often designed with different nominal flow rates Qnom , A and Qnom ,B .

The second characteristic curve of each continuous valve is specifically

predetermined by its fabrication and is specified in the data sheet as valve
characteristic curve. It specifies the relationship between the valve voltage
and valve displacement y . Figure 19 illustrates a typical characteristic
curve for a 4/3-way proportional valve, which has nominal flow rates of
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Qnom, A = 85 l min and Qnom, B = 47 l min each for the connections A and B. The
characteristic curve is usually less steep in the area of lower input voltages,
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an area known as the micro-control range, and then goes into a steeper
part of the characteristic curve.
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Figure 19: Valve characteristic curve: excerpt from the data sheet of a 4/3-way proportional valve
3.3.4 (Pressure) relief valve

Pressure relief valves limit the maximum pressure on their input to a
(usually) mechanically-adjustable value, thereby fulfilling functions that are
mostly safety-relevant. They are an important component of every
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hydraulic system. A relief valve should always be designed directly behind

the system pressure pump to limit the maximum system pressure. The
symbol for a pressure-relief valve for a fixed pressure is specified in Figure
15(b).
3.3.5 Pressure control valves

A pressure control valve keeps the output pressure at a constant value that
can usually be adjusted mechanically. It is sometimes used to maintain a
constant pressure level in a hydraulic system. The symbol is specified in

Figure 15(c). The disadvantage of this type of valve is a noticeable drop in

pressure when the input pressure on the valve is very high, thereby
causing significant power loss through the valve.
3.3.6 Check valves
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Check valves ensure that fluid can only flow in one direction. Its symbol is
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depicted in Figure 15(a).
Task: Applications for hydraulic valves
For the valves that have been presented, choose the hydraulic circuits
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where you think the corresponding valve is used appropriately.
Task: Electrical counterparts
Try to find the corresponding counterparts in electrical circuitry for the

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types of valves that have been presented.
3.4 Pipe layout

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Every hydraulic system has a pressure lines for high pressure (code letter P
for 'pump') and for low pressure (code letter T for 'tank').
Additionally, leakage lines (code letter L or Y) are often used to dispense of

leakage oil that leaks from gaps in the seal in piston machines, and which
must be removed pressure-free from the housing.
Servo-hydraulic systems also use separate control oil lines (code letter X)
to provide pressurizing medium to the hydraulic piloting stages. This
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measure can be compared with the separation of the signal and main
circuits in electronics.
Lines can be designed as pipes, tubing or hoses, whereby hoses are of

course much softer in regard to their volume constancy under high
pressures and therefore significantly reduce the effective bulk modulus of
pressure medium and line (see also Section 3.6).

3.5 Accumulators
Hydraulic accumulators serve as pressure reservoirs and act as dampers
for high frequency pressure shocks waves. Hydraulic accumulators are able
to receive a certain amount of fluid under pressure and release it back with
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minimal loss.
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In principle, the design involves a pressure-resistant housing, a gas filling
(usually nitrogen) and a dividing element between gas and pressure fluid.
Membrane, bladder and piston accumulators are common designs. Figure
20 shows the principle design of a bladder accumulator.
3.6 Working fluids ep

Figure 20: Principle design of a bladder accumulator
In addition to the primary tasks of transferring force and energy as well as

providing the volumetric connection between pumps and actuators, the
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working fluid also fulfills secondary functions such as reducing the wear
caused by friction between moving parts by providing lubrication,
protection against corrosion and dissipating frictional heat.
Pressure fluids have two properties that are significant for the regulation of
hydraulic systems: Compressibility and viscosity.
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Working fluid volume is not constant; instead it decreases under the

influence of compressive forces. The compressibility coefficient is defined
as
1 ∂V
β =− ⋅ .
V0 ∂p
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The compressibility is usually specified by the bulk modulus
1
E=
β
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The bulk modulus for conventional hydraulic oils is in the range of
E = 16000bar and is greatly decreased, particularly in the lower pressure
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range, when air bubbles are dissolved in the oil. The effective bulk modulus
for a hydraulic system depends on the pipe layout and on the use of hoses.
The viscosity determines the load-bearing capacity of a hydraulic fluid and

is greatly decreased as the temperature rises, which has a significant
influence on the damping of hydraulic controlled systems. A viscosity value
that is too low causes high leakage losses and a viscosity that is too high
causes losses resulting from internal fluid friction. Higher viscosity results
3.7 Sensors
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in thicker fluid (less capable of flowing).
As in all closed loop control-related questions, the same holds true in

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hydraulics: You can't control more than you can measure!
Additional sensors can often be used to improve the control quality in a

hydraulic system if the sensors supply sufficiently accurate measurement
values quickly.
The following are the most important sensors for a hydraulic positioning or
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force control system:
3.7.1 Position sensors (Encoder)

This sensor is the most important one for position control because it
measures the controlled variable. For more about this, see the Training
Module TM 400 (The Basics of Electrical Drive Technology).
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The following sections will deal mostly with an SSI encoder because it is
the most commonly used encoder. Recommended Automation Studio
settings for such an encoder can be found in the appendix.

3.7.2 Pressure sensors

Hydraulic systems usually have a manometer near the system's high-
pressure point. A manometer is an easy-to-read pressure gauge on which
the measured pressure is most commonly indicated using a pointer (or
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sometimes using a digital display). However, these measurement devices
only provide information about the momentary mean pressure and are not
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suitable when pressure changes rapidly.
Electrical pressure sensors are used to quickly and accurately record

pressure values or pressure curves that can be used for controlling
pressure. There are 3 main principles here:
• Piezoelectric pressure sensors: Piezo elements, that are

compressed by fluid pressure, create voltage proportional to the
•
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pressure, which is amplified by a measurement amplifier.
Strain gauge pressure sensors: Strain gauges are attached to a
membrane. Deformation of the membrane under pressure causes
a change in resistance which is evaluated by a measuring bridge.
Piezo-resistive pressure sensors: These types of sensors are
highly compact. They work like strain gauge sensors, except for
the silicon membrane, which contains semiconductor material so
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that the strain gauge bridge is able to be implemented within the
membrane.
3.7.3 Load cells

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Load cells also function on the pressure sensor principles. However, they
are built in such a way so that the measurement signal represents force
instead of pressure.
Flow rate sensors, temperature sensors, and rotational angular encoders

are also used for motors, and can be efficiently and effectively integrated in
a closed loop control system.
With the exception of the position sensors, most sensors in hydraulics

provide voltage signals in the ranges 0 V to 10 V, and -10 V to 10 V or
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current signals in the ranges 0 to 20 mA and 4 to 20 mA.

Hydraulic drives as control systems
4. HYDRAULIC DRIVES AS CONTROL SYSTEMS

There are two methods for controlling hydraulic drives. This leads to so
called pump-controlled and valve-controlled hydraulic systems. We will
discuss these two concepts in the sequel.
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4.1 Pump-controlled system
In a pump-controlled system, the flow rate through an actuator is set
directly by adjusting a hydraulic generator (i.e. a pump). This allows the
pump-controlled system to operate without loss, without taking the loss of
efficiency caused by the components into consideration. The pump only
outputs as much energy as the motor actually consumes. A configuration
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like the one in Figure 21 can also be called a hydrostatic gear.
In the layout illustrated in Figure 21, the speed of the motor can generally
be reached by adjusting the pump or changing the pump speed. In
principle there are two possible designs:
•
•
Variable displacement pump driven by motor at constant speed,
Fixed displacement pump with speed-controlled drive motor.
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Compared to the valve controlled system described below, this results in
the following disadvantages of
• the generally more complicated construction and resulting higher

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costs,
• and the greater control time constant because the inertia of
rotational machines must be moved.
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Figure 21: A hydrostatic gear.

4.2 Valve controlled system

In valve controlled systems, the energy flow is directed through variable
hydraulic resistances (valves). This type of controller is generally very
precise, but has the disadvantage that substantial losses occur because the
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orifice losses from the valve are conceptually used for control. Figure 22
shows a simplified circuit diagram for a valve controlled system. The system
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pressure ps is kept constant by the pressure-relief valve. The flow rates in
the hydraulic cylinder Q pos and Qneg are set by accordingly opening the
continuous valve.
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Figure 22: Simplified circuit diagram of a valve controlled system
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Note:
The labels Q pos and Qneg are based on the idea that Q pos is positive for a
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movement in the positive direction of movement (deploying pistons),

whereas Qneg is positive for a movement in negative direction of
movement (retracting pistons).
Some applications are able to combine the pump controlled system with the
valve controlled system in such a way that utilizes the benefits of both
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methods.

4.2.1 System properties in a valve controlled system

To improve our knowledge of the closed loop control concept for hydraulic
drives, we will review the most important properties of a typical hydraulic
drive, as illustrated in Figure 22:
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• Piston area ratio of the hydraulic cylinder:
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Generally, the two surfaces of the hydraulic cylinder differ,
whereby different gain factors result in both directions of action.
• Valves:
Continuous valves (proportional or servo valves) represent
hydraulic resistances, which can be controlled by specifying the
valve voltage. However, the flow through the valve is dependent
on the pressure difference. This dependency is non-linear.
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Furthermore, the flow through the valve is also dependent on the
control voltage on the valve, even at constant pressure difference,
according to a valve characteristic curve (usually specified in the
data sheet).
• Hydraulic cylinder chambers:
The chambers filled with fluid in a double-acting hydraulic
cylinder act like (pre-stressed) springs on the hydraulic pistons.
The spring constant is greatly dependent on the piston position.
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The spring is very taut at the edge, however the piston position
for the softest hydraulic spring depends on the piston area ratios
of the pistons.
• Working fluid (hydraulic oil):
The viscosity of the oil depends greatly on the temperature.
Robustness must always be taken into consideration when
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dealing with hydraulic drive control (unlike control of electro-

mechanical drives for example) because the flow properties of the
fluid, and therefore the behavior of the hydraulic drive, change
with viscosity.
Some of these non-idealities are known and can therefore be specifically

accounted for within the framework of a closed loop control system. It is
difficult to determine the extent of other non-idealities (such as the
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temperature dependency of the oil) and are compensated for by making

the controls as robust as possible.

4.2.2 The hydraulic drive simulation task HydSim1

Because a valve controlled system is often used for industrial applications,
simulation tasks are available for simulating a hydraulic system.
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Figure 23: Simulation model of a valve controlled hydraulic system
In the following section, we will use the package HydSim1, which primarily
models the layout illustrated in Figure 23. All relevant physical parameters
can be adjusted here so that they correspond to an existing industrial
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system, in order to simulate the behavior of the system based on the

physical relationships. The model inputs are the valve voltage and the
external force.
The package HydSim1 also includes a documentation which describes its

usage and the corresponding model.
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Task: Implementing the simulation model
Use the documentation for the package HydSim1 to get familiar with its
functionality. Drag the task to a task class with the correct cycle time
and transfer the task to the CPU. Try to confirm some of the properties
described earlier, such as the non-linearities of the valve, by setting a
suitable valve voltage UValve in the simulation.

Closed loop control concept
5. CLOSED LOOP CONTROL CONCEPT

The following section will present a closed loop control concept for
hydraulic drives. We will start out by taking a look at the hardware
configuration. The closed loop control strategies implemented in the B&R
library AsHydCon will then be covered step-by-step.
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5.1 Hardware configuration
The hardware concept for controlling B&R hydraulic drives is based on the
standard product palette instead of special hardware modules.
• Control algorithms are processed on an SG4-CPU. A wide range

of CPUs (PowerPanel, X20-CPUs, APC) is available for selection
based on the level of performance needed (determined by the
•
time).
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number of hydraulic axes and the desired cycle and reaction
Sensors for position, pressure, force and flow are connected to

the remote backplane X2X via corresponding input modules.
Manipulated variables for valve positions are transferred to the
valves via analog output modules that are also connected via
X2X.
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The high degree of modularity and granularity makes it possible to
implement highly cost-effective solutions in IP20 as well as IP67 (or mixed).
Figure 24 shows an example of a hardware configuration for controlling 3
hydraulic cylinders, operating a displacement pump using an analog
output, and controlling additional electrical axes. Two of these are then
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used to directly control hydraulic axes via servo motors on ACOPOSmulti.

Additionally, safety-related inputs and outputs as well as visualization
applications are also connected.
Note:
Chapter 9.1.4 in the appendix contains further details about hardware

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selection and hardware configuration in Automation Studio.

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Figure 24: Hardware configuration example
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5.2 Closed loop control strategies using the AsHydCon library

The function blocks implemented in the B&R hydraulics control library
AsHydCon are tailored to valve controlled hydraulic systems because they
are used throughout industry and demand specialized control concepts.
The function blocks have a modular design. This means they succeed with
a low number of measurement signals, but also make it possible to
counteract specific unfavorable system characteristics by integrating
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additional measurements.
In most cases: the more information available to a control block, the better
the control quality can and will be.

In the following sections, we will be using the task from section 1.2
presented in Figure 4 to go through the range of functions for position
control provided in the AsHydCon library. We will then continue expanding
the range of functions moving toward superseding force control.
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The goal of a position control task is usually not to hold a certain position,
but rather to change the position of a (hydraulic) drive with great precision
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and to move to a target position.
The AsHydCon library provides two approaches for doing this:
• The HCRP2P_Cont() block is used to move from the current

position of a hydraulic drive to a specified target position as fast
as possible (within the limitations of the settings)
• To do this however, movement profiles are often required, which
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are subject to predefined limitations in regard to maximum
acceleration and/or jolt as well as maximum speed. For this case,
the AsHydCon library provides the HCRSPF() block for creating a
movement profile with corresponding characteristics. Other
control blocks are used for implementing this and other
movement profiles (such as a position profile for an electrical
axis).
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sset UValve Valve sact
Target-
HCRP2P_Cont &
position
- Cylinder
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Figure 25: Control concept for HCRP2P_Cont
sset UValve Valve sact

Profile- Controller &
generator
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- Cylinder
Figure 26: Control concept using profile generator

We will discuss both approaches in the sequel to illustrate the fundamental

differences.
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5.2.1 Structure of the Hydraulic Control Library AsHydCon
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The library AsHydCon includes different types of function blocks. Its scope
covers the range of
• Signal processing
Basic filtering function blocks like PT1-, PT2- DT1-, DT2-, notch-filters
or delay elements.
• Servo correction
•
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Function blocks which implement the correction of the valves flow-
rate pressure dependency and allow to directly control the flow
through the valve. The servo-correction blocks differ in the used
measurement signals and whether they are used for position- or
force-control.
Creation of characteristic curves

These function blocks can be used to store characteristic curves and,
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especially, to invert the characteristic curve of a valve.
• Controller function blocks

This category includes basic PID-controllers (with hydraulic specific
functionality) and complex controller function blocks which realize
hydraulic controllers for specific applications. In principle these
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complex controller blocks include a basic PID controller and a specific

servo correction block. We will be discussing their differences and
will be using these function blocks throughout chapter 5.2.
• Additional function blocks

There are additional function blocks , e.g., for movement profile
generation (HCRSPF()), auto-tuning, ramp-generation and jolt-free
switching between inputs.
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A complete list of function blocks available within the library AsHydCon is

provided in the appendix in chapter 9.6.

5.2.2 The AsHydCon sample packages

The hydraulic control library AsHydCon comes with a set of sample
packages which provide tasks for certain hydraulic standard setups, to
serve as templates for application tasks. These packages are available via
the Automation Studio Help.
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In many cases these tasks can directly be used to control hydraulic axes,
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whereas only parameter adjustments have to be made. The following
picture shows an overview of the available tasks together with the
hydraulic setup covered by it.
AsHydCon sample Used library

package name functions Used sensors
Lib_AsHydCon1
Lib_AsHydCon2
ep HCRP2PCont()
HCRSPF()
HCRs_Cont()
Cylinder Position
Cylinder Position
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HCRSPF() Cylinder Position
Lib_AsHydCon3 Cylinder Pressures
HCRs_Cont_p()
System Pressure
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HCRSPF() Cylinder Position

Lib_AsHydCon4 HCRRampGen() Cylinder Pressures
HCRsF_Cont_p() System Pressure
Figure 27: Overview of the AsHydCon example packages

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Going from package Lib_AsHydCon1 to Lib_AsHydCon4 the implemented

controllers grow in complexity, however, in the same way their
performance can increase if it is parameterized correctly. In the following
sections the different control strategies are elaborated and it is shown, how
additional controller complexity improves the control performance.

Note:
Whenever using one of the sample packages, please read the

documentation in the Doc-folder of the package carefully to understand
its usage and structure.
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5.2.3 Point-to-point positioning with the HCRP2P_Cont() function block
The HCRP2P_Cont() function block is already a complete controller block,
which functions without having to define a movement profile. The goal of
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this block is to implement the fastest possible movement from a start to a
target position within the manipulated variable limitations and specification
of PID parameters. The simple interface is shown in Figure 28.
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Figure 28: Interface of HCRP2P_Cont()

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The sample package LibAsHydCon1 in the Automation Studio Help

implements a simple position controller using the HCRP2P_Cont() function
block. The basic structure of the control loop is depicted in Figure 29.

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Figure 29: Structure of the control loop realized in HydCon1
The task consists of a part implementing an IO-scaling, which is used to

convert the raw sensor data from the input modules to physical values
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used in the controller. In addition the controller is parameterized and its
output is used to drive the valve.
Figure 30 is a schematic representation of the hardware configuration

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being used. It contains an analog output module for valve control and an
encoder module for measuring the current position.
Task: A simple hydraulic position controller
Use the task HydCon1 in the sample package Lib_AsHydCon1 in order to

control the simulation model HydSim1. Use the documentation of the
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package Lib_AsHydCon1 and the Automation Studio Help to familiarize

yourself with how this control task and the used function block works.

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Figure 30: Hardware configuration for position control of the linear drive
5.2.4 Movement profile specification with the help of the HCRSPF() function block
The HCRSPF() function block now allows you to generate a movement
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profile (starting from the current position) which can be defined by

specifying the target position and a maximum speed, acceleration and
deceleration (in positive and negative direction of movement respectively)
as well as optional limitation of the occurring jolt.
Task: Smooth movement profile generation

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Use the HCRSPF() function block to generate a cyclic movement profile

for the differential cylinder between two positions s1 and s2 . A prepared
program part for this task can be found in the Automation Studio Help
for the library AsHydCon.

Note:
Be aware of the fact that control is not yet active, because the
movement profile created by the movement profile generator
represents a set position curve. Nevertheless, the circumstance of the
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hydraulic drive should be accounted for during the configuration of this
set profile.
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These types of cyclic movement profiles occur in almost all machine-
related tasks because recurring tasks are most often handled by the drive.
Apart from that, these types of cyclic movement profiles are also useful
when commissioning systems in order to perform any required controller
tuning.
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5.2.5 Closed loop control with position feedback only
In contrast to section 5.2.3 we will deal from now on with control concepts
as depicted in Figure 26.
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Like in section 5.2.3 we again assume in this sections that only the position
signal sact of the position encoder can be used as measurement signal for
the closed loop control. The control voltage of the proportional valve is
available as manipulated variable. Thus, the hardware configuration of
Figure 30 applies.
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In this section we do not want to take into account any information on our
hydraulic drive. The function block HCRSPF() is used to generate a desired
position movement profile. In addition the controller function block
HCRs_Cont() is used as simple PID controller. The control concept for this
setup is depicted in Figure 31.
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sact
Scaling
sset UValve
HCRSPF HCRs_Cont y HydSim1
(PID)
-
Figure 31: Control concept for simple position control with HCRSPF() and HCRs_Cont()

Task: Simple hydraulic position control with profile generation
Realize the control loop of Figure 31 with the simulation task HydSim1.
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As a starting point you can use the package Lib_AsHydCon2.
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Please read the documentation of the package Lib_AsHydCon2 carefully
to understand the structure of the controller task and the necessary
parameterization.
To use the function block HCRs_Cont() as PID controller set the

parameter vyServoMode = 0x08. Take care of the correct scaling of the
controller output to calculate the corresponding valve voltage.
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The stiffness of the control loop can now be influenced by adjusting the
proportional gain Kp (parameter pPID_Para_s).
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Note:
The Update parameter for the control block HCRs_Cont() must be set to
TRUE to apply the changed control parameters.
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Look at the position lag error during movement. You will notice that it has a
different size for positive and negative movement.
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5.2.6 Position control with Kp adjustment

The different effective surfaces of a differential cylinder result in different
lag errors for a closed control loop, in which the control parameters of a
linear controller are not adjusted according to the direction of movement.
In the servo compensation mode vyServoMode = 0x06, a direction-

dependent adjustment of the controller's proportional gain is automatically

made in the HCRs_Cont() function block, so that the control behavior is

nearly the same in both directions of movement.
Task: Hydraulic position control with profile generation and

Kp-adjustment
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Expand the task for position control so that the HCRs_Cont() function
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block can be operated with the setting vyServoMode = 0x06. The two
cylinder surfaces Apos and Aneg of the differential cylinder (parameter
pSystem_Para) must also be specified in addition to the block.
Compare the control behaviour (especially the lag errors) of the two
servo compensation modes 0x08 and 0x06!
(servo compensation)
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5.2.7 Compensation of the valve's flow rate pressure characteristic curve
If, as additional measurement signals

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• either the chamber pressures of the cylinder chambers are
directly available, measured using pressure gauges in the
chambers,
• or the resulting force of the hydraulic cylinder is available,
measured using force gauges on the cylinder,
• or if the resulting force is known, such as the gravitational, or
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frictional forces,
then this information can be used to estimate the chamber pressures in
order to determine the pressure drop across the valve. If the relation
between the flow rate and pressure difference on the valve discussed in
section 3.3.3 is known, then this characteristic curve can be inverted again.
Assuming that this characteristic curve is exactly inverted, the controller
can then accurately define the flow rate needed to implement a desired
piston movement by activating the valve accordingly.
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5.2.7.1 Estimate or measurement of the process force

If part of the force that is dedicated to the hydraulic drive is known from
the drive construction, then the following equation
p pos Apos − pneg Aneg = FP
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can be used to determine the chamber pressures p pos and pneg from the
process force FP , assuming that the movement is steady. These chamber
pressures can then be used to calculate the pressure drop across the valve
edges.
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servo-compensation using process force
Use again the sample task HydCon2 with the setting vyServoMode =
0x00 for the HCRs_Cont() function block, by which the servo
compensation just described is applied under the assumption of a
constant supply pressure. Furthermore the following parameters must
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be specified for the function block as far as they are known from the
configuration of the simulation model HydSim1:
• System parameter pSupply_max and pSupply
(parameter pSystem_Para)
• Valve parameters Qnom_pos, Qnom_neg, pDelta_nom
(parameter pValve_Para)
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• Process force Fp_Cyl

• Direction-dependent frictional forces Ff_Cyl_pos and
Ff_Cyl_neg
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In some hydraulic applications, the system pressure is not always constant

at all operating points. A change in system pressure over a large range
(e.g. more than 10 % of the nominal pressure) can have negative effects on
the control behavior. In this case, it can be useful to use a measuring
sensor for the system pressure and to provide the HCRs_Cont() function
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block with the actual measured value. Figure 32 shows the hardware
configuration being used. The process forces used in this mode are also
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indicated.
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Figure 32: Hardware configuration with system pressure sensor and process force details
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Tasks: Servo-compensation with variable system pressure
Change your control task so that you use the variable provided as
measurement input for the system pressure of the simulation task
HydSim1 for the pSupply parameter (element of pSystem_Para). Define
vyServoMode = 0x02 for the servo compensation under the assumption
of a variable system pressure.

5.2.7.2 Configuration with cylinder pressure sensors

In Figure 33, the hardware configuration for the position control of a
hydraulic drive with 2 additional pressure gauges is specified for the two
cylinder chamber pressures. If the chamber pressures are made directly
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available to the control block after being measured, then they no longer
have to be estimated and the exact pressure difference throughout the
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valve is known (within the limitations of the measurement accuracy).
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Figure 33: Hardware configuration for operation with two pressure sensors


servo-compensation using cylinder pressure signals
Use the sample package Lib_AsHydCon3 in which the controller function

block HCRs_Cont_p() is used for position control instead of the
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previously used HCRs_Cont().
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This block uses the two inputs pCyl_pos and pCyl_neg for the cylinder
chamber pressures to realize the servo compensation for the valve
instead of the inputs for the process force and the frictional forces.
5.2.8 Valve linearization
usually determined by its design.

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As discussed in section 3.3.3, the characteristic curve of a valve is a
relationship between control voltage and the valve opening, which is
The valve characteristic curve can be inverted in the controller function

block because this relationship is specified in the data sheet of each valve,
and is therefore known.
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Linearization of the valve is implemented within the framework of the
AsHydCon using the HCRLinValve() function block, which is connected
after the control block. The input of the HCRLinValve() block is the desired
valve opening Qy and the output is the required valve voltage Uy. Figure 34
shows the interconnection between this function block and the
HCRs_Cont() block.
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HCRs_Cont_p
sset vre Qy Uy
HCRPID HCRvyServo_F HCRLinValve
- p
sact
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Figure 34: Connecting the HCRLinValve() function block to the HCRs_Cont() block

Tasks: Realizing the valve linearization
Use the sample package Lib_AsHydCon2 or Lib_AsHydCon3 to

implement a valve linearization by connecting the output of the
controller block HCRs_Cont() or HCRs_Cont_p() to the HCRLinValve()
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function block.
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Make sure to configure the block in exactly the same way as specified in
the documentation of the package HydSim1. It is only useful to invert
the valve characteristic curve when working with the correct data.
5.2.9 Velocity feed forward
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On the hydraulic cylinder, the necessary flow into (or out of) the
corresponding cylinder chamber Q pos (or Qneg ) can be estimated because
of the conservation of mass at predefined speed v of the piston over the
piston surface area Apos and Aneg (see Figure 35). The following formula is
valid for movements at constant speed and load
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Q pos Qneg
v= =− .
Apos Aneg
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Figure 35: Simplified circuit diagram for a valve controlled system

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The movement profile, which is created using the HCRSPF() movement

profile generator, provides the set speed curve as well as the set position
curve. This can be used to calculate and feed-forward the flow needed for
the current set piston speed and therefore the necessary valve opening.

Figure 36 illustrates the principle design of this sort of feed-forward.
Using this type of feed-forward reduces the job of the PID controller to
comparing deviations from the nominal behavior. As a result, it can
generally be set faster (increasing the value of Kp) which allows it to react
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more quickly to disturbances. Furthermore, the lag error is always smaller
when speed feed-forward is used correctly than when it is not used at all.
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Tasks: Realizing velocity feed-forward
Expand the control task by making the signal vset , which is created by
the HCRSPF() function block, available to the HCRs_Cont() or
HCRs_Cont_p() block.
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Can you use this method to reduce the lag error during movement at
constant speed?
vset
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HCRs_Cont
vabs
sset vre Qy Uy
HCRPID l HCRvyServo_Fp HCRLinVal
-
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sact
Figure 36: HCRs_Cont block speed feed-forward.

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5.2.10 Fine positioning

The integrator of the PID controller can also be configured to achieve a
specified target position independent of the process force as accurately as
possible.
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To achieve satisfactory results in this relationship, a few properties of the
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hydraulic system should be taken into consideration.
A position-controlled hydraulic cylinder is essentially a controlled system

which behaves like an integrator – a constant flow rate into the cylinder
causes a linear increase of the actual position. Controlled systems
including integrator action could actually be controlled precisely using just
a P-controller. This generally also applies to position-controlled hydraulic
cylinders, but not at very low speeds. The integrating behavior of the
actual position.
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controlled system, consisting of valve and cylinder, is suspended due to
leakage effects. This would result in a lasting deviation between set and
The integral element on the controller, which is only activated at very low
speeds, shortly before the target position is reached is one solution
approach for this behavior. Otherwise, it remains switched off to prevent
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overshoots.
Additionally, the integrator must be switched off again when static friction
and very low deviations between set and actual position are present, in
order to prevent stick-slip effects. This effect occurs when the controlled
drive stops due to the influence of static friction before the desired target
position has been reached. However, this breaks away again after a certain
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amount of time and stops at a different position due to the charging

integrator. The result is that this drive never comes to a stop, but instead
constantly oscillates, which is of course not desired. Control deviation
when the target position is reached with static friction can never be
completely avoided through closed loop control. Instead, attempts can
only be made to prevent this stick-slip effect.
Reasonable conditions for activating the integrator in the controller could

include:
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• Actual speed value < specified limit value

(e.g. 2 .. 20 mm/s).
• Set speed value < specified limit value
(e.g. 0 .. 1 mm/s).
• Position error value > required precision.
The integrator is activated when all of these conditions are met.

The integrator can be switched off again when the required precision is
reached or a new movement is started.
One of the following two conditions would be sufficient for this:
• Set speed value > specified limit value
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(e.g. 0 .. 1 mm/s).
•
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Position error value < required precision.
Task: Fine positioning of a hydraulic drive
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Expand your task by adding an integrator to the position controller
depending on the movement conditions specified above. Try to see how
precise you can position the simulation model!
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Thus, the first part of the task introduced in section 1.2 has now been
covered in great detail and solved using the functionality of AsHydCon.
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5.2.11 Position / force control

In this section, we will now cover the second part of the task from section
1.2 – superseding force control.
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The process force FP can be determined by either using the pressure
gauge and the following formula:
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p pos Apos − pneg Aneg = FP
or by using a load cell.
The following cycle should be implemented within the framework of this

control task:
•
•
•
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Position-controlled movement from s1 to s2
Starting from a definable threshold value for the press force:
Switching to force control
Controlled increase of press force to target force, maintaining the

target force and force reduction until the threshold value is
achieved
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• Position-controlled movement from s2 back to s1
Two points are decisive for a superseding closed loop control system as
required here:
• Definition of suitable and consistent switching conditions.

• Jolt-free switching between the superseding controllers.
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Both points are accounted for by the HCRsF_Cont_p() control block.

Depending on the operating mode, this uses one of the two force control
blocks HCRF_Cont() or HCRF_Cont_p() in addition to the HCRs_Cont_p()
position control block and the HCRJoltFree() block for jolt-free switching
between position and force control.
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Task: Include material model to simulation
To prepare for the next task, configure a material model for your
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simulation model in such a manner so that the material contact takes at
position sContact = 400mm . You can do this by adding another task which
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changes the value of the external force Fextern of the simulation model
depending on the cylinder position sCyl.
Task: Implement superseding position/force control
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Use the package Lib_AsHydCon4 together with the simulation model
HydSim1 to realize position control and superseding force control for
the hydraulic drive with material contact at position sContact = 400mm .
Force control is activated when a definable contact pressure is exceeded

on the material. Here the HCRsF_Cont_p() block is used instead of the
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HCRs_Cont_p() function block. The HCRRampGen() block is additionally
used to create the ramp for the force build-up.
As no additional force sensor is used, the press force is calculated with

the formula p pos Apos − pneg Aneg = FP .
Again, read the package documentation carefully to understand the

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functionality of the package.

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5.2.12 Auto-tuning
For a configuration with a hydraulic cylinder and a continuous valve as
presented in Figure 4, a value that is ideal for most applications can be
determined based on theory for the controller gain Kp of the position
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controller.
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The HCRAutotune() function block determines this optimum value for Kp
using the hydraulic system's most significant physical parameters. This
value can then be applied to the position control block being used.
Note:
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The value determined here for Kp is a reference value for position
control only, that can be applied usefully for many systems because it
represents a compromise between speed and robustness of the control
loop. In most cases, operating the system with this setting is not a
problem. Furthermore, it can be used as a starting point for subsequent
manual tuning.
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Task: Autotuning for position control
Use the HCRAutotune() function block to find a suitable value for the Kp
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parameter of the PID controller in the HCRs_Cont() or HCRs_Cont_p()

block. Use the values defined in the simulation task for the function
block configuration.
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Axis couplings
6. AXIS COUPLINGS
Real machines often require synchronizing multiple axes in a controlled
manner (in some cases also different types – electrical and hydraulic).
Depending on the complexity of the synchronization conditions, there are
many different ways to establish axis links.
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6.1 Application solution
A simple link between a hydraulic axis and another hydraulic or electrical
axis can be implemented in the application code. In the following example,
an instance of the HCRSPF() specifies the set position (set trajectory) of
axis 1. The set position of axis 2 is linked to the set position of axis 1 via a
simple (affine) transformation.
Program example:
axis1HCRSPF();
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axis1HCRSPF.s_end:= gVisu.set.sCyl;
axis1HCRSPF.Init:= TRUE;
axis1HCRs_Cont.s_set := axis1HCRSPF.s_set;
axis1HCRs_Cont.v_set := axis1HCRSPF.v_set;
axis2HCRs_Cont.s_set := axis1HCRSPF.s_set*k12 + offset12;
axis2HCRs_Cont.v_set := axis1HCRSPF.v_set*k12;
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6.2 Connecting to ACOPOS
One real and one virtual axis can be calculated on any ACOPOS servo
drive. A virtual axis makes it possible to calculate a set position as non-
linear function of the set and actual position of another real or virtual axis,
which can be located on another ACOPOS servo drive (cam profile
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functionality).
A virtual axis on an ACOPOS can also be used to generate set positions for
a hydraulic axis. This set position (and the set speed) are transferred
cyclically to the CPU via POWERLINK, where the position control loop is
implemented for the corresponding axis.
After adjusting the physical dimensions accordingly (usually a conversion

from increments to millimeters), the set value is connected with the
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position controller for the hydraulic axis.
In this case, make sure to account for the latencies resulting from the
communication (see also section 6.4).

Axis couplings
6.3 Connecting to ARNC0

The ARNCO soft CNC system can be used when more hydraulic axes than
electrical axes are present on ACOPOS servo drives and complex axis links
(cam profiles) must be implemented.
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In addition to the actual CNC functionality, ARNC0 also offers the possibility
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to implement cam profile links between any axes on a CPU.
Figure 37 is a schematic diagram of how to link a soft CNC task with a

hydraulic controller. The Soft CNC system calculates set positions for the
electrical as well as for the hydraulic axis. For the electrical axis, these
reference values are forwarded to the position control loop in the ACOPOS
unit. The set positions for the hydraulic axis are forwarded to the
corresponding position control loop for the hydraulic axis, implemented in
Target system
ARNC0
Set
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a hydraulic task on the target system.
position
Axis 1
ACOPOS
Electrical
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Soft CNC Set
position axis
Axis 2
Valve voltage
Hydraulic Hydraulic
control Actual axis
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position
Figure 37: Schematic diagram of how to link with ARNC0

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Axis couplings
6.4 Exact synchronization

If position set values are transferred to an axis control loop via
communication channels (e.g. POWERLINK or other fieldbuses), then these
position set values arrive delayed by the communication latency.
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To achieve highly-precise synchronization of a system with multiple axes,
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the position set values of axes with low or no communication latencies
must be delayed.
This is implemented in the ACOPOS INIT parameter module for an

ACOPOS axis using the parameters t_total and t_predict, which forwards a
position set value to the position control loop with a delay (see Figure 38).
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Figure 38: The parameters t_predict and t_total in the ACOPOS NC-Init table
The HCRFIFO() function block from the AsHydCon library offers an identical
functionality for delaying signals (e.g. for a hydraulic axis) as shown in the
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following program example.
s1_set := ax1_HCRSPF.s_set;
ax1_s_Cont.s_set := s1_set;
ax2_FIFO.x := s1_set;
ax2_FIFO();
ax2_s_Cont.s_set := ax2_FIFO.y;
An instance of the HCRSPF() (ax1_HCRSPF variable) creates a movement

profile, which is forwarded directly to the position control loop of hydraulic
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axis 1 (ax1_s_Cont) and delayed to that of the second axis (ax2_s_Cont) by

using an instance of the HCR_FIFO() block. This example contains
ax1_s_Cont and ax2_s_Cont control blocks with the type HCR_s_Cont.

Safety
7. SAFETY
7.1 Safety concept

In many applications, the software safety concept is not designed until after
the main functionality of the system has been completed. This can cause
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difficulties and even delays in commissioning because the application code
must often be revised.
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Note:
A sophisticated and seamless safety concept for an application is more

important than any sophisticated and optimized control concept
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because a safety flaw can cause personal and/or material damage.
However, a control concept can always be "touched up" as long as the
general safety conditions were planned for.
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A safety concept for a hydraulic application must always include a SafePLC,
such as B&R's Integrated Safety, which shuts down the drive or puts it into
a safe state if the valid operating range has been exceeded. It is important
to determine whether the SafePLC being used is specifically designed to
protect personnel or whether there is any guarantee that this SafePLC will
prevent potential damage to the system when shutting down in all
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operating states. Integrated Safety Technology handles a wide range of

safety demands in a highly flexible manner (Smart Safe Reaction), which
makes it easier to create a custom safety system for different applications.
The application now has to be adapted to the functionality of the SafePLC,

because personal and material damage must be prevented at all times,
particularly during commissioning. At least the following safety-related
aspects must be taken into consideration for a hydraulic application:
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Safety
7.2 Limitations and prohibited operating areas

A cyclic check must occur in the application task to monitor whether all
measurement signals (and any values calculated from the measurement
values) are within the permissible range so that an error can be output or
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the system stopped immediately in the event of emergency.
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Mandatory measurement signals and valid ranges include;
• Position, which is limited by a maximum and minimum position.
• Speed, limited by a maximum value.
• Pressure, in particular the system pressure, is limited by the amount

of pressure which has been specified for the system (pipe layout,
components).
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Particularly in a hydraulic application, the correct sequence is important
when stopping and closing rotating machines and other moving parts as
well as connected valves.
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For example, take a look at the hydraulic circuit diagram in Figure 39 as
expansion to the diagram in Figure 4. In this diagram, the two safety valves
V2 and V3 are arranged in such a manner so that cylinder chambers A and
B will close if a malfunction occurs, which automatically stops the cylinder.
Make sure in the application that operation with the proportional valve V1
is only possible when the safety valves V2 and V3 are open.
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Inversely, the situation could arise whereby excessive pressures occur in

the cylinder chambers by closing the switching valves V2 and V3 while the
cylinder is in motion at high speed and the load has a high moment of
inertia. Generally, these sort of situations are handled by suitable hydraulic
connections with pressure-relief valves. However, this sort of operating
state should generally be avoided.
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Safety
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Figure 39: Hydraulic circuit diagram with safety valves
Specification of the movement profile using the HCRSPF() trajectory

generator is an important part of the B&R hydraulic control concept. This
can be configured in such a way so that software position limits are
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adhered to. However, you must still make sure that these limitations are
only based on the reference position and not on the actual position of the
drive.
The HCRSPF() block provides the Brake input in order to stop a drive
because of a value that is unknown to the HCRSPF() block (e.g. system
pressure exceeds the permissible value). Brake is used to stop the drive
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without exceeding the configured limitations.

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Safety
7.3 Integrating the SafePLC

As mentioned earlier, safety equipment which directly shuts down the
system via a SafePLC and thereby reduces the risk of danger, is included in
the design of all systems or machines which pose potential personal or
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material threat.
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These sort of inputs can also be integrated in the application task. In most
cases, the application must ensure (in a time frame specifically intended for
this purpose), that no direct material or indirect personal damage occurs
when the machine is forced to shut down by the safety equipment.
In order to do this, the safety equipment and the machine application must
always be adapted to one another.
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7.4 Testing the implemented safety functions
An implemented safety function must also undergo targeted testing
without putting the system or personnel at risk. Function tests on the
application should not be made until the application's safety net is working
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properly.
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Summary
8. SUMMARY
Automation Studio and the B&R product palette offer comprehensive
functionality for implementing closed loop controls for hydraulically-driven
axes, axis links and the corresponding maintenance and diagnostics.
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An important factor for successful application of hydraulic drive controls is
keeping a clear and organized overview of the implemented AsHydCon
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library functionality so that the right decisions can be made for a given
hydraulic task.
All that is left to do, particularly when working with standard applications,
is to configure the function blocks.
This means that the application engineer is able to maintain an overview of

the application at all times and set up each specific stage of the system's
functionality individually.
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Figure 40: The B&R Hydraulic - Demo

Appendix
9. APPENDIX
9.1 Solution guide
9.1.1 Hydraulics circuit diagram
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The hydraulics circuit diagram should be studied and discussed with the
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machine operator before the beginning of each hydraulics project.
9.1.2 Machine description

The information for configuring the AsHydCon function block relies
significantly on the valves and the hydraulic drive in use, e.g. a linear
actuator. This information can be found on the corresponding data sheet.
Figure 41 and Figure 42 show a section of an ATOS proportional valve data
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sheet, in which the most important sizes, nominal flow rate and nominal
pressure difference are marked.
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Appendix
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Figure 41: Section 1 from the ATOS proportional valve data sheet
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Appendix
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Figure 42: Section 2 from the ATOS proportional valve data sheet
The valve characteristic curves are taken directly from the data sheet.
Figure 43 shows an additional section from the data sheet, which reflects
the valve characteristic curves in various valve designs.
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Figure 43: Valve characteristic curves from the ATOS proportional valve data sheet

Appendix
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Figure 44: Sections 1 and 2 from the ATOS servo cylinder data sheet
Figure 44 and Figure 45 show sections from the ATOS servo cylinder data
sheet.

Appendix
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Figure 45: Section from the ATOS servo cylinder data sheet

Appendix
9.1.3 Hardware selection

Choosing the right hardware depends significantly on the number of
hydraulic axes to be operated and the required reaction time.
Recommended values for selecting a reaction time are provided in the
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following Table 2.
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Medium level control Reaction time approx.
quality and dynamics 2ms
High level control quality Reaction time approx.

and dynamics 1ms
Highest level control Reaction time approx.

quality and dynamics 0.5ms
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Table 2: Relationship of reaction time and control quality, i.e. dynamics
The following Table 3 provides additional recommend values for selecting

the appropriate CPU for a predefined reaction time and number of axes.
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PP400 or 1 – 2 hydraulic axes with a reaction
X20CPx484 time of approx. 1500 µ s
X20CPx485 Up to 4 hydraulic axes with a

reaction time of approx. 1000 µ s
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X20CPx486 Up to 2 hydraulic axes with a

reaction time of approx. 500µ s
Up to 4 hydraulic axes with a

APC620 Up to 16 hydraulic axes with a

Up to 10 hydraulic axes with a

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2 hydraulic axes with a reaction

time of approx. 400 µ s
Table 3: CPU selection

Appendix
The reaction time consists of
• reading in the measurement signals from the input modules into

the computer via the X2X Link,
• processing the measurement signals and determining the output
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values by the CPU,
• issuing the output sizes to the output module via the X2X Link.
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The reaction time can be determined using the following formula:
Reaction time = cycle time of the task class

+ 2 x X2X Link cycle time
+ module delay (max. 65µ s )
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The Excel sheet in Figure 46 can be used to determine the smallest
possible X2X Link cycle time as well as the I/O communication time for a
given I/O configuration, cable length and X2X setting in Automation Studio.
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Appendix
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Figure 46: Excel sheet for calculating the minimum X2X Link cycle time
As is evident in the sheet, the minimum cycle time is achieved if the setting
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in Automation Studio "Allow asymmetric In/Out size" = "ON" for the X2X
Link configuration.
With this setting, a configuration with an X20AI4 module, an X20AO2

module and 2 X20DC1 or X20DS1 modules results in a minimum cycle time
of 95µ s .

Appendix
9.1.4 Settings in Automation Studio

The following guidelines should be observed in order to achieve the
minimum reaction time for the given hardware configuration:
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Generally, a hydraulic controller is executed in the fastest task class. The
coordination of the task class cycle time with that of the X2X Link is
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important: the cycle time of the task class must always be an integer
multiple of the X2X Link cycle time in order to allow synchronous
operation.
An X2X Link cycle time of 200 µ s can be set for most hydraulic control
loops. A value of 400 µ s is recommended as the cycle time for the highest
task class, if the CPU performance permits it. The stack of the task class
must generally be increased compared to the standard setting. In order to
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avoid memory problems, it is best to start with a value of 65535 bytes.
This, as well as additional settings regarding the task class, can be found in
Figure 47; those regarding X2X Link are found in Figure 48.
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Figure 47: Task class settings

Appendix
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Figure 48: X2X Link settings
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Figure 49: System timer settings

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Appendix
For the frequent case that an SSI encoder is used for position
measurement, the required settings for an X20DS1119 module, which can
perform SSI communication, are given in Figure 50. The required data can
be found in the SSI encoder data sheet.
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Figure 50: Configuration of the SSI interface module X20DS1119
SSI transducers which can perform synchronized measurement are

preferable, because these transducers can be synchronized to the X2X link
cycle time. If the X2X link cycle time is smaller than the allowed range of
the transducer, optionally a pre-scaling can be used in the X20DS1119
module. To do this, “prescaled system timer” is selected as Update cycle
together with an an appropriate value for the cycle prescaler.

Appendix
9.1.5 Selection of function blocks in AsHydCon

The following flow chart should serve as selection guide for the available
function blocks within the framework of the AsHydCon library.
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Position or force
Position control tasks? Force
control
control
Position
Simple (and fast) and force Which measurement
movements from control signals are available?
start to finish? (Selection of force
(No jolt limitation control function block)
Yes
Function block
HCRP2P_Cont:
requirements)
No trajectory generator
necessary here.
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Specification of
movement profile
required?
(With acceleration-
Chamber
pressures
Block:
HCRF_Cont_
p
Force
Block:
HCRF_Cont
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and jolt limitation)
Yes
Block HCRSPF:
Which measurement
signals are available? Position +
(Selection:
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chamber
control block) pressures
Position
Which measurement
Control block: signals are available?
Control block:
HCRs_Cont (Selection:
HCRs_Cont_p
(Optional: Use of a control block)
known load force) Chamber Force
pressures
Block: Block:
Valve characteristic
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HCRsF_Cont_p HCRsF_Cont
curve known?
Yes
Block: HCRLinValve
Figure 51: State diagram for selecting the control blocks

Appendix
In addition, these can be used within a framework of several control blocks,

depending on additional measurement signals (e.g. system pressure) in
order to improve control quality (e.g. system pressure information can be
made available to the servo compensation blocks).
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9.2 Commissioning
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In general, the supplier of a hydraulic
system must provide commissioning
instructions for the system, which Table of Contents
should be consulted before each
commissioning.
General
In addition, several important points Safety Remarks
regarding commissioning are Hydrostatic Accumulator
addressed in this section:
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It is important to carefully plan the
commissioning of hydraulic systems
and develop a step-by-step concept
that allows the function of all
required components so that they
Transport
Storage Conditions
Assembly
Operating Fluids
Commissioning
Safety Remarks for Commissioning
Filling
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can be properly operated. Flushing before Start-Up
Electrical Connectors
Most importantly, this requires Pumps and Instrumentation
appropriate operating modes. In Power-Up
addition to automatic operation, the System Bleeding
option of manual operation must Filter
always be available as well. With
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complex systems, it is a good idea to

implement a suitable visualization for manual operation in advance.
The following components should be observed during a function test:
• Valves: Question: "Does the valve response (open/closed for

switching valves, and/or position of continuous valves) match the
current control?"
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• System pressure pump: Question: "Does the direction of rotation

of the electric motor match the designated direction of rotation
for the pump?"
• Important: To test, only produce small, slow movements.
Special: When tuning the electric motor, make sure that it does
not execute any undesired movements during the tuning.

Appendix
• The system pressure is kept at the lowest possible value for the
commissioning process. The purpose of this is to protect all
components because hydraulic oil is still generally very
contaminated.
• Valve control: The combination of safety- and proportional valves
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must be taken into account for valve control. In general, the safety
valves are opened in one step when a proportional valve is still
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closed and the proportional valve is manually controlled in order
to confirm the direction of action (there is no control block used
here; instead the valve voltage is directly specified).
• During manual operation and at low system pressure, the entire
operating area (e.g. a hydraulic cylinder) should be run through
several times, so as to remove potential air in the fluid before the
system pressure is increased.
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Gradual implementation of automatic operation commences only after it
has been confirmed that all components are functioning.
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9.3 Controller settings
The AsHydCon library control blocks are generally configured in two steps:
• using valve parameters, valve characteristic curves, cylinder

dimensions, etc., which can all be found in data sheets.
• By configuring a higher-level PID controller.
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The first point was described in detail in this training module. The training
module TM 261 "Closed loop control with LoopConR" contains a lot of
practical information regarding the second point. In what follows, you will
find a potential configuration procedure for the available control blocks
within the AsHydCon library framework.
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Appendix
• A recommended value for the proportional gain K p of the

position controller can be determined by entering several physical
parameters using the HCRAutoTune() function block.
• As a test experiment, it is recommended that you specify a
cyclical position profile that can be implemented using this P
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controller. Now, K p can be adjusted. An increase makes the
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control loop faster, but increases vibration tendency. It is most
important to test the controller at different piston positions
because the natural frequency and vibration tendency changes
with operation point.
• In the following step, a velocity feed forward can be used to
simplify the task for the controller. In general, with a correct feed-
forward, the value of K p for the controller can be increased
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further; see also section 5.2.9 of this training module.
Finally, the remaining control error can be reduced by inserting an
I-element. Note that I-elements with high static friction can lead to
so-called stick-slip effects; see also section 5.2.10 as well as the
AsHydCon example project.
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9.4 Controller optimization
AsHydCon library control blocks have many options which allow them to
be optimized for specific types of tasks. Some examples are provided
below.
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9.4.1 Process force compensation

As already illustrated in section 5.2.7.1, this can be specified for the
HCRs_Cont() control block when the load force is known, so that it can be
used for valve control.
9.4.2 Acceleration compensation

Acceleration forces can also be interpreted as dynamic load forces. In
order to improve the control sequence behavior regarding acceleration
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movements, the force m × a to be overcome can be specified with the mass

m and the acceleration a .
9.4.3 State feedback controller

Thanks to the modularity of the function blocks, the standard control loop
observed within the AsHydCon framework can also be expanded in the
direction of a state controller.

Appendix
Figure 52 shows the principle idea behind this. If, as depicted here, the
current acceleration aact is available, it can be compensated for accordingly
in the control loop. The manipulated variable generated by this controller is
thus a direct function of the state variable path (P-element), speed (D-
element) and acceleration. This type of controller is called a state feedback
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controller.
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HCRs_Cont
sset vSe Qy,s UValve

HCRPID HCRvyServo_Fp HCRLinValve
- +
vadd
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Figure 52: Idea of expansion in the form of a state feedback controller
Ka aact
sact
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9.5 Further literature
The following literature is recommended as potential references:
• John S. Cundiff: „Fluid Power Circuits and Controls“, CRC Press, New
York, 2002, ISBN 0-9493-0924-7
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• Herbert E. Merritt: “Hydraulic Control Systems”, John Wiley & Sons,

New York, 1967, ISBN 0-471-59617-5
• H. Murrenhoff: „Grundlagen der Fluidtechnik. Teil1: Hydraulik“

Institut für fluidtechnische Antriebe und Steuerungen, RWTH Aachen,
ISBN 3.89653-205-3
• B. Manhartsgruber: „Servohydraulik“ Vorlesungsskriptum,

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Institut für Maschinenlehre und hydraulische Antriebe, Joh. Kepler

Universität Linz, URL: http://imh.jku.at/ftp/index.en.php

Appendix
9.6 Overview of AsHydCon library function blocks
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Appendix
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Appendix
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Overview of training modules
TM210 – The Basics of Automation Studio TM600 – The Basics of Visualization

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TM211 – Automation Studio Online Communication TM610 – The Basics of ASiV

TM213 – Automation Runtime TM630 – Visualization Programming Guide
TM220 – The Service Technician on the Job TM640 – ASiV Alarm System, Trend and Diagnostic
TM223 – Automation Studio Diagnostics TM670 – ASiV Advanced
TM230 – Structured Software Generation
TM240 – Ladder Diagram (LAD) TM700 – Automation Net PVI
TM241 – Function Block Diagram (FBD) TM710 – PVI Communication
TM246 – Structured Text (ST) TM711 – PVI DLL Programming
TM250 – Memory Management and Data Storage TM712 – PVIServices
TM261 – Closed Loop Control with LOOPCONR TM730 – PVI OPC
TM400 – The Basics of Motion Control TM800 – APROL System Concept

TM410 – The Basics of ASiM TM810 – APROL Setup, Configuration and Recovery
TM440 – ASiM Basic Functions TM811 – APROL Runtime System
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TM441 – ASiM Multi-Axis Functions TM812 – APROL Operator Management

TM445 – ACOPOS ACP10 Software TM813 – APROL XML Queries and Audit Trail
TM446 – ACOPOS Smart Process Technology TM830 – APROL Project Engineering
TM450 – ACOPOS Control Concept and Adjustment TM840 – APROL Parameter Management and Recipes
TM460 – Starting up Motors TM850 – APROL Controller Configuration and INA
TM480 – Hydraulic Drive Control TM860 – APROL Library Engineering
TM865 – APROL Library Guide Book
TM500 – The Basics of Integrated Safety Technology TM870 – APROL Python Programming
TM510 – ASiST SafeDESIGNER TM890 – The Basics of LINUX
TM540 – ASiST SafeMC

Appendix
All registered trademarks are the property of their respective owners.

We reserve the right to make technical changes.
©2009 by B&R. All rights reserved.
0109
t TM480TRE.00-ENG
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Overview of training modules
Error! Cannot open data source.

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Contact (Headquarters)
Weblink
Internationality
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t

Training modules: TM210 – The Basics of Automation Studio

TM211 - Automation Studio Online Communication

TM213 – Automation Runtime

TM223 – Automation Studio Diagnostics

TM400 – The Basics of Motion Control

Software: AR 2.80 and higher

2 TM480 Hydraulic Drive Control

3.2 Displacement devices: Pumps and motors

4. HYDRAULIC DRIVES AS CONTROL SYSTEMS 29

4.2 Valve controlled system 30

5. CLOSED LOOP CONTROL CONCEPT 33

6.1 Application solution 55

Hydraulic Drive Control TM480 3

4 TM480 Hydraulic Drive Control

About the training module structure:

We will begin by introducing a type of task that occurs frequently in

hydraulic drive technology. Throughout the training module, we will learn

We will start by looking at a few basic principles of hydraulics as a way of

Material for more advanced tasks and exercises is provided in the

Hydraulic Drive Control TM480 5

6 TM480 Hydraulic Drive Control

1.2 A hydraulic task

Application examples which switch from one of these operating modes to

Figure 3: Granulate molding press

A rough hydraulic diagram for this sort of system is illustrated in Figure 4.

Figure 4: Rough hydraulic diagram for cylinder control

Hydraulic Drive Control TM480 7

In an initial step, a position controller should be developed for a system

In a second step, a change from position control to force control should

8 TM480 Hydraulic Drive Control

The affect of a force on a stationary fluid propagates in all directions

The hydrostatic press is an example of a simple application, see also Figure

Figure 5: Hydrostatic press

The pressure p is represented as force per surface, therefore

Hydraulic Drive Control TM480 9

Figure 6: Pressure distribution in a cup of coffee

The pressure in a container is not constant throughout its depth because

10 TM480 Hydraulic Drive Control

In fact, depending on the depth ∆h , the pressure in the container increases

Figure 7: Electrical and hydraulic resistance

However, there are two main differences:

Hydraulic Drive Control TM480 11

2.3.1 Flow in narrow gaps and pipes:

Figure 8: Laminar pipe flow with speed profile

with the flow rate Q (e.g. in l

) and a resistance value. In this case of

Usually, pipes in hydraulic systems are designed to promote laminar

12 TM480 Hydraulic Drive Control

2.3.2 Flow through (sharp edged) orifices:

with a constant K H , which depends on the geometry and characteristics of

It is important that the pressure loss coefficient K H in this case is not

Hydraulic Drive Control TM480 13

2.4 Comparison between electrical engineering and hydraulics

Current I [ A] Flow rate Ql 

Electr. Linear, Hydraulic Linear,

14 TM480 Hydraulic Drive Control

3. HYDRAULIC DRIVE SYSTEM STRUCTURE

• System pressure pump: Driven by an electric motor, this pump's

Hydraulic Drive Control TM480 15

• separate air bubbles in the pressure fluid,

Figure 10 shows the symbol for the hydraulic tank.

Figure 10: Hydraulic tank symbol

3.2 Displacement devices: Pumps and motors