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AUTO-CALIBRATION AND CONTROL APPLIED TO ELECTRO-HYDRAULIC VALVES
EXPERIMENTS ON HUSCO BLUE TELEHANDLER August 18, 2006 PATRICK OPDENBOSCH Graduate Research Intern INCOVA (262) HUSCO International W239 N218 Pewaukee Rd. Waukesha, WI
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MOTIVATION HUSCO’S CONTROL TOPOLOGY Steady State Mapping (Design)
US PATENT # 6,732,512 & 6,718,759 Steady State Mapping (Design) Inverse Mapping (Control) Hierarchical control: System controller, pressure controller, function controller HUSCO OPEN LOOP CONTROL FOR EHPV’s
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MOTIVATION HUSCO’S CONTROL TOPOLOGY Steady State Mapping (Design)
US PATENT # 6,732,512 & 6,718,759 Steady State Mapping (Design) Inverse Mapping (Control) Hierarchical control: System controller, pressure controller, function controller
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MOTIVATION Time Commanded Kv Actual Kv Commanded Velocity
Actual Velocity Time
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MOTIVATION Flow conductance online estimation
Accuracy Computation effort Online inverse flow conductance mapping learning and control Effects by input saturation and time-varying dynamics Maintain tracking error dynamics stable while learning Fault diagnostics How can the learned mappings be used for fault detection
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PRESENTATION OUTLINE MOTIVATION TOPIC REVIEW SETUP IMPROVEMENTS
MAPPING LEARNING & CONTROL EXPERIMENTAL RESULTS FUTURE WORK CONCLUSIONS
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TOPIC REVIEW PURDUE PAPERS
Liu, S. and Yao, B., (2005), Automated modeling of cartridge valve flow mapping, in Proc: IEEE/ASME International Conference on Advanced Intelligent Mechatronics pp Liu, S. and Yao, B., (2005), On-board system identification of systems with unknown input nonlinearity and system parameters, in Proc: ASME International Mechanical Engineering Congress and Exposition Liu, S. and Yao, B., (2005), Sliding mode flow rate observer design, in Proc: Sixth International Conference on Fluid Power Transmission and Control pp
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TOPIC REVIEW CATERPILLAR PATENTS NEW PATENTS
Aardema, J.A. and Koehler, D.W., (1999) System and method for controlling an independent metering valve, U.S. Patent (5,960,695) Aardema, J.A. and Koehler, D.W., (1999) System and method for controlling an independent metering valve, U.S. Patent (5,947,140) Kozaki, T., Ishikawa, H., Yasui, H., et al., (1991) Position control device and automotive suspension system employing same, U.S. Patent (5,004,264) NEW PATENTS Reedy, J.T., Cone, R.D., Kloeppel, G.R., et al., (2006) Adaptive position determining system for hydraulic cylinder, U.S. Patent ( ) Du, H., (2006) Hydraulic system health indicator, U.S. Patent (7,043,975) Wear, J.A., Du, H., Ferkol, G.A., et al., (2006) Electrohydraulic control system, U.S. Patent ( )
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TOPIC REVIEW CATERPILLAR PATENTS
“Adaptive Position Determining System for Hydraulic Cylinder” Limit Switches
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TOPIC REVIEW CATERPILLAR PATENTS
Long-Jang Li, US Patent 5,942,892 (1999) CATERPILLAR PATENTS 5,004,264 “Position Control Device and Automotive Suspension System Employing Same” Position Detector
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TOPIC REVIEW CATERPILLAR PATENTS
“Electrohydraulic Control System” Position/Velocity sensor Adaptive scheme: no details found
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TOPIC REVIEW CATERPILLAR PATENTS
7,043,975 “Hydraulic System Health Indicator” Using Lyapunov stability theory Health Monitoring using Bulk modulus and other model-based parameters (Position/velocity sensor) Based on pump pressure discharge dynamics or cylinder head end control pressure
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PRESENTATION OUTLINE MOTIVATION TOPIC REVIEW SETUP IMPROVEMENTS
MAPPING LEARNING & CONTROL EXPERIMENTAL RESULTS FUTURE WORK CONCLUSIONS
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SETUP MOTION CONTROL Independent coil current control
SIEMENS controller Supply & return pressure from ISP Supply KSA KSB HUSCO Blue Telehandler KAR KBR Return Boom Function Boom Function Kinematics
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HUSCO Blue Telehandler
SETUP MOTION CONTROL Independent coil current control SIEMENS controller Supply & return pressure from ISP PS HUSCO Blue Telehandler Diesel Engine Pump Filter Tank Relief Valve Unloader KSA KSB KAR KBR Boom Cylinder PA PB PR
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PRESENTATION OUTLINE MOTIVATION TOPIC REVIEW SETUP IMPROVEMENTS
MAPPING LEARNING & CONTROL EXPERIMENTAL RESULTS FUTURE WORK CONCLUSIONS
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Pressure override for pump pressure control (ISP code)
IMPROVEMENTS PUMP CONTROL Ripples Pressure override for pump pressure control (ISP code)
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IMPROVEMENTS PUMP CONTROL
DATA SHOWN: Margin added on retract metering mode (PB signal is user commanded, not actual workport pressure) PUMP CONTROL Current override for unloader coil current control (ISP code)
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Current override for unloader coil current control (ISP code)
IMPROVEMENTS PUMP CONTROL Current override for unloader coil current control (ISP code)
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IMPROVEMENTS ANTI-CAVITATION Unconstrained Operating Point
KOUT_MAX m = R3/4 PIN_MIN Unconstrained Operating Point Keq_dPmin KIN_MAX Keq POUT_MAX Constrained Operating Point
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IMPROVEMENTS ANTI-CAVITATION Cavitation
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IMPROVEMENTS ANTI-CAVITATION Flow Sharing No Cavitation
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IMPROVEMENTS LEARNING Supply KSA KSB EXTEND KAR KBR Return
Boom Function
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IMPROVEMENTS LEARNING Supply KSA KSB RETRACT KAR KBR Return
Boom Function
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IMPROVEMENTS LEARNING Supply KSA KSB EXTEND/RETRACT KAR KBR Return
Boom Function
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PRESENTATION OUTLINE MOTIVATION TOPIC REVIEW SETUP IMPROVEMENTS
MAPPING LEARNING & CONTROL EXPERIMENTAL RESULTS FUTURE WORK CONCLUSIONS
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MAPPING LEARNING & CONTROL
LEARNING APPLIED TO NONLINEAR SYSTEM MAPPING TO BE LEARNED (simplified) Expected curve shift
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MAPPING LEARNING & CONTROL
LEARNING APPLIED TO NONLINEAR SYSTEM MAPPING TO BE LEARNED (simplified) Expected curve shift
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MAPPING LEARNING & CONTROL
LEARNING APPLIED TO NONLINEAR SYSTEM CONTROL DESIGN Tracking Error: Error Dynamics: Linear Time Varying System
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MAPPING LEARNING & CONTROL
LEARNING APPLIED TO NONLINEAR SYSTEM CONTROL DESIGN Error Dynamics: Deadbeat Control Law: Closed loop
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MAPPING LEARNING & CONTROL
LEARNING APPLIED TO NONLINEAR SYSTEM CONTROL DESIGN Deadbeat Control Law: Proposed Control Law:
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MAPPING LEARNING & CONTROL
Nominal inverse mapping Inverse Mapping Correction icmd KV NLPN Servo EHPV dKV Adaptive Proportional Feedback Jacobian Controllability Estimation
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MAPPING LEARNING & CONTROL
LEARNING APPLIED TO NONLINEAR SYSTEM CONTROL DESIGN Proposed Control Law: Closed loop
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MAPPING LEARNING & CONTROL
IDENTIFICATION DESIGN Methods: Least Squares (Recursive) Noise rejection Poor time varying parameter tracking capabilities (add covariance reset and forgetting factor – dynamic or static) New research suggest variable-length moving window* Gradient Based Sensitive to noise Better time varying parameter tracking capabilities Gradient step size must be chosen carefully Identification of time varying parameter for a linear system (*) Jiang, J. and Zhang, Y. (2004), A Novel Variable-Length Sliding Window Blockwise Least-Squares Algorithm for Online Estimation of Time-Varying Parameters, Intl. J. Adaptive Ctrl & Signal Proc., Vol 18, No. 6, pp
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MAPPING LEARNING & CONTROL
IDENTIFICATION DESIGN Approximations: Previous-point Linearization Stack Operator
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MAPPING LEARNING & CONTROL
IDENTIFICATION DESIGN Approximations: Previous-point Linearization Stack Operator Properties
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MAPPING LEARNING & CONTROL
IDENTIFICATION DESIGN Approximations: Previous-point Linearization Stack Operator Properties
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MAPPING LEARNING & CONTROL
IDENTIFICATION DESIGN Approximations: Previous-point Linearization
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MAPPING LEARNING & CONTROL
IDENTIFICATION DESIGN Approximations: Previous-point Linearization How are (dJ,dQ) and (J*,Q*) related?
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PRESENTATION OUTLINE MOTIVATION TOPIC REVIEW SETUP IMPROVEMENTS
MAPPING LEARNING & CONTROL EXPERIMENTAL RESULTS FUTURE WORK CONCLUSIONS
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Every valve uses a generic Table
EXPERIMENTAL RESULTS Nominal inverse mapping icmd KV Servo EHPV dKV Every valve uses a generic Table
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EXPERIMENTAL RESULTS PUMP CONTROL: MARGIN
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EXPERIMENTAL RESULTS
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EXPERIMENTAL RESULTS
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EXPERIMENTAL RESULTS PUMP CONTROL: PS_SETPOINT
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EXPERIMENTAL RESULTS
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EXPERIMENTAL RESULTS
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EXPERIMENTAL RESULTS icmd KV dKV NLPN EHPV Nominal inverse mapping
Inverse Mapping Correction icmd KV NLPN Servo EHPV dKV
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EXPERIMENTAL RESULTS PUMP CONTROL: MARGIN
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EXPERIMENTAL RESULTS
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EXPERIMENTAL RESULTS
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EXPERIMENTAL RESULTS PUMP CONTROL: MARGIN
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EXPERIMENTAL RESULTS
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EXPERIMENTAL RESULTS
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EXPERIMENTAL RESULTS PUMP CONTROL: PS_SETPOINT
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EXPERIMENTAL RESULTS
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EXPERIMENTAL RESULTS
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EXPERIMENTAL RESULTS icmd KV dKV NLPN EHPV Nominal inverse mapping
Inverse Mapping Correction icmd KV NLPN Servo EHPV dKV FIXED Proportional Feedback
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EXPERIMENTAL RESULTS PUMP CONTROL: MARGIN
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EXPERIMENTAL RESULTS
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EXPERIMENTAL RESULTS
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EXPERIMENTAL RESULTS
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EXPERIMENTAL RESULTS
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EXPERIMENTAL RESULTS
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EXPERIMENTAL RESULTS
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EXPERIMENTAL RESULTS
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EXPERIMENTAL RESULTS SHOW LEARNED MAPS
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PRESENTATION OUTLINE MOTIVATION TOPIC REVIEW SETUP IMPROVEMENTS
MAPPING LEARNING & CONTROL EXPERIMENTAL RESULTS FUTURE WORK CONCLUSIONS
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FUTURE WORK Improve EHPV performance using adaptive proportional feedback Study convergence properties of adaptive proportional input and its impact on overall stability Incorporate fault Diagnostics capabilities along with mapping learning Refine pump controls
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PRESENTATION OUTLINE MOTIVATION TOPIC REVIEW SETUP IMPROVEMENTS
MAPPING LEARNING & CONTROL EXPERIMENTAL RESULTS FUTURE WORK CONCLUSIONS
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CONCLUSIONS The performance of the INCOVA control system under Ps_setpoint and margin pump control was improved when using mapping learning as oppose to using fixed inverse valve opening mapping. Satisfactory experimental results were obtained on applying feedforward learning and fixed proportional control to four (4) EHPVs Experimental verification of improved commanded velocity achievement using mapping learning was presented The need for good velocity sensor was observed (potential idea for customized sensor was presented)
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CONCLUSIONS More refined code (constraints) allowed better control
Unresolved Issues still exist with parameter estimation and adaptive proportional control portion Experimental validation of faster mapping learning with proportional feedback in place (fixed) Learning grid can be fixed based on curve shifting behavior
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QUESTIONS? ???
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