Hydraulic Servo and Related Systems

ME4803 Motion Control

Wayne J. Book HUSCO/Ramirez Chair in Fluid Power and Motion Control G.W. Woodruff School of Mechanical Engineering Georgia Institute of Technology

Hydraulics is Especially critical to the Mobile Equipment Industry

References
1. Norvelle, F.D. Fluid Power Control Systems, Prentice Hall, 2000. 2. Fitch, E.C. and Hong I.T. Hydraulic Component Design and Selection, BarDyne, Stillwater, OK, 2001. 3. Cundiff, J.S. Fluid Power Circuits and Controls, CRC Press, Boca Raton, FL, 2002. 4. Merritt, H.E. Hydraulic Control Systems, John Wiley and Sons, New York, 1967. 5. Fluid Power Design Engineers Handbook, Parker Hannifin Company (various editions).

The Strengths of Fluid Power

(Hydraulic, to a lesser extent pneumatic) High force at moderate speed High power density at point of action
Fluid removes waste heat Prime mover is removed from point of action Conditioned power can be routed in flexible a fashion

Potentially Stiff position control Controllable either electrically or manually

Resulting high bandwidth motion control at high forces

NO SUBSTITUTE FOR MANY HEAVY APPLICATIONS

Difficulties with Fluid Power

Possible leakage Noise generated by pumps and transmitted by lines Energy loss due to fluid flows Expensive in some applications Susceptibility of working fluid to contamination Lack of understanding of recently graduated practicing engineers
Multidisciplinary Cost of laboratories Displaced in curriculum by more recent technologies

Voltsamp

System Overview
Rpm- Pump torque Flowpress. sion line

Electric or IC prime mover

Transmis & valve

Flow- Motor or press. cylinder

Rpmtorque or force

Coupling mechanism

The system consists of a series of transformation of power variables Power is either converted to another useful form or waste heat Impedance is modified (unit force/unit flow) Power is controlled Function is achieved

Rpmtorque or force

Load

Simple open-loop open-center circuit

cylinder

Actuating solenoid Spring return

Pressure relief valve 4-way, 3 position valve filter Fixed displacement pump Fluid tank or reservoir

Simple open-loop closed-center circuit

Closed-loop (hydrostatic) system

Motor Check valve

Variable displacement reversible pump

Drain or auxiliary line

Pilot operated valve

Proportional Valve

Basic Operation of the Servo Valve

(single stage)
Flow enters Flow exits Torque motor moves spool right

Torque motor moves spool left

Positive motor Negative rotation motor rotation

Orifice Model
Q ! Cd Ao 2 (p V

Cd ! orifice flow discharge coef. Ao ! orifice flow area ! w x

4 Way Proportional Spool Valve Model

Spool assumptions q1 ! q2 No leakage, equal actuator areas q1 ! C ps  p1 x, C ! a constant Sharp edged, steady flow q2 ! C p2  p0 x Opening area proportional to x ps  p1 ! p2  p0 ! p2 Symmetrical Load pressure : (p ! p1  p2 Return pressure is zero p  (p p  (p so : p1 ! s ; p2 ! s Zero overlap 2 2 Fluid assumptions ps  (p q ! C ps  p1 x ! C x p0 ps p0 1 2 Incompressible Mass density V x

p2, q2

p1, q1

Dynamic Equations (cont.)

Expand in a Taylor series to first order to linearize xq q1 ! q1  1 xx
xq1 xx

xq ((p  (p )  - (high order terms) ( x  x )  1 x! x x(p x ! x (p ! (p (p ! (p

ps  (p ; 2 xq1 x(p

Taking partial derivatives :

x! x (p ! (p

!C

x!x (p ! (p

C x 2 2 p s  (p

Choose operating point, commonly x ! 0; (p ! 0, at which q1 ! 0 xq1 xx

x! x (p ! (p

p0

ps

p0 x

ps xq1 !C ! K1 ; 2 x(p

x!x (p ! (p

! K2 ! 0
p2, q2 p 1, q 1

Dynamic Equations: the Actuator

q1 Change in volume y

 q1 ! K1 x  K 2 (p ! K1 x ! Ay

Change in density

Net area Ap

If truly incompressible:

Specification of flow without a response in pressure brings a causality problem For example, if the piston has mass, and flow can change instantaneously, infinite force is required for infinite acceleration Need to account for change of density and compliance of walls of cylinder and tubes

Compressibility of Fluids and Elasticity of Walls

Bulk modulus : F ! V xp N xV m 2 1 1 dV 1 d ( M / V ) ! ! F V dp V dp

For the pure definition, the volume is fixed.

More useful here is an effective bulk modulus that includes expansion of the walls and compression of entrapped gasses

F dM ! q dt ; dp ! VV

q dt

1 1 d ( M / V ) 1 1 xM M xV  2 ! ! F eff V dp V V xp V xp
Using this to solve for the change in pressure

F eff dp ! VV

 dM ! k M dt ! k q dt

Choices for modeling the hydraulic actuator

With no compliance or compressibility we get actuator velocity v as q 1/AV

dv/dt

With compliance and/or compressibility combined into a factor k And with moving mass m q k dt p A /m dv/dt

Manufacturers Data: BD15 Servovalve on HAL

Manufacturers Data: BD15 Servovalve on HAL

Two-stage Servo Valve

Torque motor rotates flapper, obstructs left nozzle Pressure increases Spool is driven right With flapper centered the flow and pressure is balanced Feedback spring balances torque motor force

Flow gives negative rotation

Details of Force Feedback Design

2 Sharp edged orifices, symmetrical opening

Shown line to line; no overlap or underlap

Another valve design with direct feedback

Position Servo Block Diagram

Position measurement Load torque Flow gain / motor displacement

Proportional control

May be negligible

Net flow / displacement

Design of some components (with issues pertinent to this class)

The conduit (tubing) is subject to requirements for
flow (pressure drop)
2 to 4 ft/sec for suction line bulk fluid velocity 7 to 20 ft/sec for pressure line bulk fluid velocity

pressure (stress)

The piston-cylinder is the most common actuator

Must withstand pressure Must not buckle

Design Equations for Fluid Power Systems

Flow
Darcys formula Orifice flow models

Stress
Thin-walled tubes (t<0.1D) Thick-walled tubes (t>0.1D)

Guidelines
Fluid speed Strengths Factors of safety (light service: 2.5, general: 3.15, heavy: 4-5 or more)

Darcys formula from Bernoullis Eq.

4 TDh Q! (p, N R e 2000 (p ! pressure drop along the tube 128QL f D ! friction factor (depends on N R ) Q ! absolute viscosity L ! tube length (Hagen - Poiseuille law) Dh ! hydraulic diameter

LV (p ! f D 2 Dh

Q A

or

! 4 x (flow section diameter)/(section perimeter) V ! fluid mass density Q ! flow rate A ! flow section area VuDh NR ! Q u ! fluid velocity

Friction factor for smooth pipes (empirical) from e.g. Fitch

Orifice Model
Q ! Cd Ao 2 (p V

Cd ! orifice flow discharge coef. Ao ! orifice flow area

Rod is constrained by cylinder at two points Constrained by load at one point Diameter must resist buckling Theory of composite swaged column applies Composite column fully extended is A-B-E shown below consisting of 2 segments
A-B segment buckles as if loaded by force F on a column A-B-C B-E segment buckles as if loaded by F on DBE Require tangency at B

Buckling in the Piston Rod (Fitch)

Cylinder construction (tie-rod design)

Resulting loading on cylinder walls

Applicable wall thickness stress formulas

(conduits or cylinders)
Thin walled cylinders (open, or where only circumferential hoop stress is significant) (Barlow) Thick walled cylinders
Brittle materials (based on max normal stress) use Lames formula Ductile (based on max strain theory)
Open end (no axial stress) (Birnie) Closed end (cylinder bears axial stress) (Clavarino)

Expansion of cylinder based on strain = stress/(Youngs modulus)

Stress formulas
Barlow' s formula (thin, open) Clavarino's formula (closed, thick, ductile) PDi t! 2 sd D s  (1  2R ) P Di ! inside diameter

t!

sd ! design or allowable stress R ! Poisson' s ratio

2
i

 1 sd  (1 R ) P
d

! strength/(factor of safety * stress concentration)

Lame' ' s formula (brittle) Di t! 2 sd  P  1 s P d

Birnie' s formula (open, thick, ductile) Di t! 2 sd  (1 R ) P  1 s  (1 R ) P d

Results of Composite Column Model

Equating the slope of the two column segments at B where they join yields:
Ia F tan La Ib Ea I a
0.25

!  tan Lb F Eb I b

64 I b Dr ! ! diameter of rod T The first equation may be solved iteratively then solve for Dr

Composite column model matches manufacturers recommendations with factor of safety of 4

Pressure Specifications

Nominal pressure = expected operating Design pressure = Nominal Proof pressure (for test) = 2x Design Burst pressure (expect failure) = 4x Design

Pipes versus tubes

Tubes are preferred over pipes since fewer joints mean Lower resistance Less leakage Easier construction

Fittings between tube and other components require multiple seals

Flared tube design