Modeling and Simulation of EH Systems

Lecture 1: Introduction
Dr. Eng. Taher Salah El-Din

Lecture 1 1
 Contents

1 Fundamentals of Electrohydraulic drives

2 Servo valves

3 Servo cylinder

4 Hydraulic fluids

5 Filters

6 Hydraulic mold oscillation system (Physical model)

Lecture 1 2
FUNDAMENTALS OF
ELECTROHYDRAULIC DRIVES

Lecture 1 3
 Fundamentals of Electrohydraulic Drives
General System Structure and Energy Flow in a Machine with
Hydraulic Drive System

ENERGY ENERGY CONVERSION ENERGY TRANSMISSION ENERGY LOAD

SOURCE (mechanical - hydraulic) and CONTROL CONVERTION
and STORAGE (hydraulic-
mechanical)

a
M Q p

A
hydraulic actuator
pumpe

B
BKM T
motor
b

Swivel motor

Generatoric Part Conductiv Part Actuatoric Part

Lecture 1 4
Requirements and applications of Electrohydraulic Drives

Wishes:

• As fast as possible

• Less stress for the structure

• Precise positioning
+/- 0,000 mm

• High work forces

 Fundamentals of Electrohydraulic Drives
Electrohydraulic System: Open Hydraulic Circuit, Valve-Controlled, System
with Impressed Pressure

• Valve Electronic may be

AA AB housed in the Control
FL cabinet or may be integrated
x, x, x
Power Transmission and Control

into the valve.

QA QB Sensor
A B • Instead of a fixed
displacement pump a
Electronic Control
P T (e. g. PLC, IPC) variable displacement pump

Signal Processing
with pressure compensation
p1
may be used. The pressure
Q1
Valve Electronic compensator limits the
n1 • Valve Control pressure p1 to a pre-set
M • Signal Amplification value by adjusting pump
flow Q1 and improves total
system efficiency.

Lecture 1 6
Axial Piston Pump - swash plate design

Lecture 1 7
SERVO VALVES

Lecture 1 8
 What is meant by Servo Hydraulics?
• In general, the term “servo” is used to describe the function in which a small input
signal produces a large output signal (amplifier).
Example:
• An input signal of low power—for example, 0.08 watts - can provide analog control
of power reaching more than 100 kW. The best known example is probably servo
steering in a motor vehicle, where the steering wheel is moved with little effort to
produce large force on the wheels.
• Servo hydraulics can be expressed as closed loop electro-hydraulic control, which
means that operation is constantly monitored by means of measurement, and
deviations from required operation are automatically corrected.
• The control parameters are mainly mechanical parameters such as displacement,
velocity, force, or hydraulic parameters such as flow or pressure.

Lecture 1 9
 Closed Loop Control
• The actual piston position is
measured and fed back as a voltage
by the feedback potentiometer.

• At the amplifier input the difference

between these two voltages, i.e. the
command feedback signal difference
or closed loop error is created.

• The error is amplified by the

amplifier and is thus able to energize
the Servo valve coil, which opens and
the piston moves .

Fig. 7 Closed loop control

Lecture 1 10
 Major applications of servo valves
Field Frequency, Hz Flow, L/min Power, kW
Vibration exciters 600 4 1.5
Aircraft nose 150 4 1.5
wheel steering
Machine tool 100 40 15
Turbine control 100 11 4.5
Injection molding 60 300 120
Flight simulators 50 190 75
Robots 40 57 22
Aircraft engine 30 15 6
fuel control
Rolling mills 30 570 225
Conveyers 15 25 10
Crawler vehicles 7 378 150
Process controls 5 7.5 3
Lecture 1 11
 Different types of Servo valves

Single stage control valve size 6, with 2- stage control valve size 10,
mechanical feedback, type 4WS1EO 6 with mechanical, and electrical
feedback,

3- stage directional servo valve size

16, 25, 32 with mechanical and
electrical feedbacks

Lecture 1 12
Servo valves
1- When the valve is de-
energised, the flapper
is centred relative to
the two pilot nozzles so
pressures on either end
of the main spool are
equal and the main spool
is also centred.

Lecture 1 13
Servo valves
2- The torque motor is
fitted with a permanent
magnet frame
surrounding the
armature.

Lecture 1 14
Servo valves
3- Passing a current
through the torque
motor coils magentises
the armature and
causes it to tilt. The
direction of the tilt is
determined by the
voltage polarity and the
amount of tilt by the
magnitude of the
current.

Lecture 1 15
Servo valves
4- The tilting of the
armature causes the
flapper to move closer
to one nozzle and
further away from the
opposite nozzle.

Lf

Lecture 1 x16
Servo valves
5-This unbalances the
pressures on either end
of the main spool ...

Lecture 1 17
 Servo valves
6- Causing the main
spool to move and flow
to pass through the
valve.
As the main spool
moves, the flapper is
dragged back to the
centre of the two
nozzles when the pilot
Trivial position of
pressures equalise and
flapper against spring
the spool stops moving.
wire stiffness

Ls  Ls

TF1  Fs1Ls  K S Ls Ls

y x
Lecture 1 18
Servo valves Incorporating Flapper Valve Amplifiers
• Construction of Single stage control valves

• The single-stage servo valve controls the

pressure difference between its two exit ports
(A and B).

• It may be used as a single stage pressure servo

valve or as a pilot controller of a multistage
8
servo valve.

• It consists of an electromagnetic torque motor The construction of a single-stage

servo valve.
(1) , a hydraulic designed as a double-jet
flapper valve (6), and an interchangeable filter
element (8).

Lecture 1 19
 Flapper Valve Amplifiers
• By communicating the control current to the coils, the torque motor
produces a torque proportional to the input current. This
proportionality is practically linear.

• The resulting torque rotates the armature

and flapper by relatively small rotational angles,

within 0.5 degree.

Lecture 1 20
 Flapper Valve Amplifiers

• The high-pressure oil is supplied to the valve

via the port (ps) and the fine filter.

• The fig. shows a double nozzle flapper valve .

This valve consists of two fixed orifices, D1

and two regulating flapper nozzles D2. The input control

pressure ps is decreased via orifices D1 and the jet nozzles D2.

• If the cross-sectional areas of the nozzles of both sides are the same, then the
same pressure drop occurs for both.

• The displacement of the flapper plate changes the throttle area of the two
regulating jet nozzles. The flapper motion to the right increases the area of the left
nozzle and decreases the area of the right nozzle .
21
Lecture 1
Principle of servo valve with mechanical feedback

22
Lecture 1
 Symbol of Servo Valve

Symbol:

4/3 electrically actuated 2-stage

servo valve, with mechanical and
electrical feed back
2-stage directional servo valve with
mechanical and electrical feedback

Lecture 1 23
Principle of S/V with mechanical and electrical feedbacks

24
Lecture 1
SERVO CYLINDER

Lecture 1 25
 Servo cylinder systems
• Servo cylinder systems are used in applications where,
1- Low friction
2- High oscillation frequencies with small amplitudes
3- Highest of dynamic responses and accuracy of the
linear drive is required such as in movement simulators,
material and component testing devices.

• Servo cylinder systems basically comprise the following devices:

servo cylinder - servo manifold and control electronics

Lecture 1 26
Stribeck curve (Stick slip behavior)

Lecture 1 27
 Friction forces comparison
Friction measurement at p = 210 bar, v) = 0.1 m/s and s = ±100 mm
s

Servo cylinder with hydrostatic taper gap bearing Hydraulic cylinder with a contact seal ring

Lecture 1 28
servo cylinder with hydrostatic tapered gap bearing
A, B= operating pressure ,
L = leakage oil
P = operating/ bearing pressure
1 = positional transducer

The bearing pressure in the taper gap

bearing is equivalent to the operating
pressure (P)

Lecture 1 29
 Servo Cylinder With Full Hydrostatic Bearing

A, B= operating pressure ,
L = leakage oil
P = operating/ bearing pressure
1 = positional transducer

The bearing pressure in the full

hydrostatic bearing is equivalent to
the operating pressure (P)

Lecture 1 30
 Servo cylinder – Annular gab seal - components
Servo cylinder – Double rod cylinder –
Annular floating gap seal design
Piston diameter 200 mm
Rod diameter 110 mm
Stroke 30 mm
1. Cushioning at both ends
2. Protection tube with flange
3. External Position transducer type EP-VO
4. 2 pressure line accumulators 1.5 liter
5. 1 tank line accumulator 1 liter
6. 2 Pressure transducer at A & B sides type HAD 3744 –A-400-000
7. Pressure relief valve type DBDS20K1X/315
8. Filter type DFBH / HC60AFE5D1.0 / -L24
9. Servo valve type: 4WSE3EE16-1X/200 B8T315Z9EM 200 l/min
10.Flushing plate DIN 16 with fastening screws of type:
HAS 16 B017-4X / M00

Lecture 1 31
 Servo manifold
• To achieve good dynamic characteristics
of hydraulic drives, the pipe lengths
between the control and servo cylinder
must be kept as short as possible. In order
to achieve this, the servo manifold is
mounted directly onto the servo cylinder.

• The piping to the power unit or to the

isolating system is via a servo manifold.
Additional functions, such as force limiting,
pilot oil and bearing oil filtration and
pressure storage are included within this
manifold.
Lecture 1 32
 Haenchen servo cylinder

leak oil Teflon tape wear ring

wiper ring
lip seal
throttling-gap
annular floating gapseal pressure drop piston sealing
International patend pending, US-Pat. 4 406 463

Lecture 1 33
 Annular floating gapseal

Not pressurized

Annular floating gapseal

Pressurized • Annular floating gap seal

– pure sealing element
deformation through pressure
– Contactless pressure drop outwards by close
throttling-gap
Q p – Beveled deformation of annular gapseal
under pressure effects centering on piston rod
p – thereby very low leakage over total pressure
range, quasi constantly
Q p
Lecture 1
34
 Closed loop position control
Electrohydraulic actuator with
integrated position sensor and in a closed loop positon Electric control
Control.
• Accurate position control (positon accuracy 2 mm)
• High dynamic response

Digital signal processing

in control loop P T
Kp
Position – (Position
Referrence signal ) +
+ e - i A B
Ka x
w
(Acceleration)
- -
Kv
(Speed)

xi
SSI-Interface
electronic

Source: Firma MTS

Lecture 1 35
HYDRAULIC FLUIDS

Lecture 1 36
Oil requirements in hydraulic systems

Lecture 1 37
 General classification of hydraulic fluids
Mineral oils Flame resistant hydraulic Biologically fast degradable
fluids hydraulic fluids
Designation Composition Designation Composition Designation Composition

H Basic oil without HFA Oil in water HETG Basis vegetable

additives Emulsion also 80 oil, mainly
- 98% water Rapeseed oil
HL with additives to HFB Water in oil HEPG Basis Polyglykol
Improvement of Emulsion also >
Corrosion 40% water
protection and
resistance to
aging
HLP like HL, however HFC Polymer solution HEES Basis synthetic
also Additives for also 35 - 55% ester
the increase of water
the wear
protectionand
resilience in the
mixed friction
area

Lecture 1 38
 Application of hydraulic fluids

Application Suitable Max operating Ambient

fluids pressure temperature
Theaters 1-2-3-4 160 bar 18 to 30 OC
Simulation and testing devices 1-2-3-4 1000 bar 18 to 150 OC
Mining 1-2-3-4 1000 bar Up to 60 OC
Special applications 2-3-4-5 250 (630) bar -65 to 150 OC

1 = mineral oil
2= synthetic hydraulic fluids
3 = ecologically acceptable fluids
4 = water , HFA , HFB
5 = special fluids

Lecture 1 39
CONTAMINATION AND FILTRATION

Lecture 1 40
 Sources of contamination

1- External contamination
2- Assembly
3- Start up contamination
4- Internal contamination
5- Wear
6- New oil
7- Repairs

Lecture 1 41
Recommended cleanliness classes for Components

Lecture 1 42
Types of filters in hydraulic power unit

Lecture 1 43
Types of Hydraulic Filters

Lecture 1 44
HYDRAULIC MOULD OSCILLATION
(HMO)

Lecture 1 45
Continuous Casting Machine

Lecture 1 46
Lecture 1 47
 HMO Description & Operation
• Two symmetrical hydraulic servo cylinders are used
to impart the oscillatory motion to the mould using
a short lever mechanism.
• The two hydraulic servo cylinders are concentric in
relation to the strand, and mounted under the
mould for transmitting the oscillating motion
directly to the mould table.
• The two Short lever mechanisms serve for guiding
the oscillating tables.

Lecture 1 48
 HMO Description & Operation
• Each of the two hydraulic servo cylinders is driven
through an independent and accurate closed loop
control system using a magnetostrictive position
transducer.

• One pressure transducer at each cylinder line A

and B for force monitoring and a double pressure
relief valve to ensure pressure limitation between
the chambers A and B of each cylinder.

Lecture 1 49
 HMO Description & Operation
• Two membrane accumulators are located at the
supply pressure side of each servo valve to ensure
a constant pressure supply in case of long strokes
and high flow rates.

• The input signals to the two control systems are

Identical, which guarantees the cylinders motion
synchronization when the corresponding
components in the two control systems are
identical.
Lecture 1 50
HMO Description & Operation

Lecture 1 51
HMO Description & Operation
ysl

xsl
425 mm
(1)

960 mm

65 mm
(2)

700 mm

1290 mm

Lecture 1 52
HMO Hydraulic Circuit

Lecture 1 53
 Factors affecting hmo operation
• Synchronization problems are recognized in these
applications after certain periods of operation due
to several factors such as leakage of hydraulic
systems, arising differences in hydraulic, electrical
and electronic components and circuits, assembly
deviations after maintenance and possible uneven
loads.
• A nonsynchronized motion of these cylinders has a
detrimental effect on the casting process and
accordingly the deviation in the positions of
cylinders is limited in practice to a certain value
which, if exceeded, causes production interruption.

Lecture 1 54
 Characteristics of servo cylinders

Piston diameter DC = 200 mm

Piston rod diameter dC = 110 mm
Cylinder annular area 𝐴𝑐𝑖 = 21901.5𝑥10−2 cm2

Piston mass 𝑚𝑖 = 200 kg

Stroke ℎ𝑖 = ±15 mm

Coefficient of internal oil leakage 𝐾𝐿𝑖 = 2 × 10−11 m5 /Ns

Coefficient of viscous friction 𝑑𝑖 = 1.75 × 105 Ns/m

Coulomb friction force 𝐹𝑐𝑖 = 10 kN

Lecture 1 55
 servo valve
• The electrohydraulic servo valves used to drive
the cylinders are three-stage servo valves.
• The integrated control electronics card is
provided with a regulated supply voltage of ±15
V, command signal of ±10 mA and a feedback
signal of ±10 V.
• The pilot oil supply to the servo valve is external
to ensure that the pilot control pressure is held
constant. It should not be less than 60 % of the
system pressure in order that the flow forces at
the control spool of the third stage do not affect
the valve controllability
Lecture 1 56
 Details of servo valve
(1) Torque motor
(2) Two control nozzles of the valve first stage
(3) First stage flapper
(4) Second stage spool
(5) Main valve control spool
(6) Mechanical feedback spring between the first
and the second stages of the valve
(7) Main spool inductive position transducer
(8) Integrated control electronics card
Lecture 1 57
Details of servo valve

Lecture 1 58
 Characteristics of servo valve

Maximum displacement of the servo valve main spool

= 1.6 mm
𝑦𝑖
= 0.7
Damping ratio of servo valve 𝐷𝑣𝑖

Servo valve natural frequency at 25 % input signal

= 816.4 rad/s
𝜔0𝑣𝑖 = 2𝜋 𝑓0𝑣𝑖

Servo valve input current 𝐼𝑖 = ±10 mA

Lecture 1 59
Non linear Simulink modeling of the HMO system

Lecture 1 60
Lecture 1 61
Thank you for your attention

Lecture 1 62