1. 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

2. Hydraulics is Especially critical to the Mobile Equipment Industry

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

4. 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

5. 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

6. System Overview
Volts-amp
Electric or IC prime mover
Transmission line & valve
Flow-press.
Motor or cylinder
Rpm-torque or force
Rpm-torque
Flow-press.
Pump
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
Rpm-torque or force
Load

7. 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

8. Simple open-loop closed-center circuit

9. Closed-loop (hydrostatic) system
Motor
Check valve
Variable displacement reversible pump
Drain or auxiliary line

10. Pilot operated valve

11. Proportional Valve

12. Basic Operation of the Servo Valve (single stage)
Flow exits
Flow enters
Torque motor moves spool right
Torque motor moves spool left
Positive motor rotation
Negative motor rotation

13. Orifice Model

14. 4 Way Proportional Spool Valve Model
Spool assumptions
No leakage, equal actuator areas
Sharp edged, steady flow
Opening area proportional to x
Symmetrical
Return pressure is zero
Zero overlap
Fluid assumptions
Incompressible
Mass density  p0 ps
p1, q1
p2, q2 x

15. Dynamic Equations (cont.)p0 ps
p1, q1
p2, q2 x

16. Dynamic Equations: the Actuator
Change in volume
Change in density y
Net area Ap q1
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

17. Compressibility of Fluids and Elasticity of Walls
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
Using this to solve for the change in pressure

18. Choices for modeling the hydraulic actuator
With no compliance or compressibility we get actuator velocity v as q
1/A
dv/dt
With compliance and/or compressibility combined into a factor k
And with moving mass m k
 dt q p
A /m
dv/dt

19. Manufacturer’s Data: BD15 Servovalve on HAL

20. Manufacturer’s Data: BD15 Servovalve on HAL

21. Two-stage Servo Valve
With flapper centered the flow and pressure is balanced
Torque motor rotates flapper, obstructs left nozzle
Feedback spring balances torque motor force
Pressure increases Spool is driven right
Flow gives negative rotation

22. Details of Force Feedback Design
2 Sharp edged orifices, symmetrical opening
Shown line to line; no overlap or underlap

23. Another valve design with direct feedback

24. Position Servo Block Diagram
Flow gain / motor displacement
Position measurement
Load torque
Net flow / displacement
Proportional control
May be negligible

25. 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

26. Design Equations for Fluid Power Systems
Flow
Darcy’s 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)

27. Darcy’s formula from Bernoulli’s Eq.

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

29. Orifice Model

30. Buckling in the Piston Rod (Fitch)
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

31. Cylinder construction (tie-rod design)
Resulting loading on cylinder walls

32. 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 Lame’s 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/(Young’s modulus)

33. Stress formulas

34. Results of Composite Column Model
Equating the slope of the two column segments at B where they join yields:
Composite column model matches manufacturer’s recommendations with factor of safety of 4

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

36. Pipes versus tubes
Tubes are preferred over pipes since fewer joints mean
Lower resistance
Less leakage
Easier construction

37. Fittings between tube and other components require multiple seals
Flared tube design

38. New Approaches: Independent Metering

39. Independent Metering: Introduction
Independent Metering Configuration F
Kat A B
Ksa
Kbt
Ksb
Tank
Pump
Check Valve x

40. Advantages of Independent Metering: Metering Modes
Energy saving potential: Regenerative flow. F
Kat A B
Ksa
Kbt
Ksb
Tank
Pump
Check Valve x
High Side Regeneration Extension F
Kat A B
Ksa
Kbt
Ksb
Tank
Pump
Check Valve x
Low Side Regeneration Extension F
Kat A B
Ksa
Kbt
Ksb
Tank
Pump
Check Valve
Low Side Regeneration Retraction F
Kat A B
Ksa
Kbt
Ksb
Tank
Check Valve
Pump x
Powered Retraction F
Kat A B
Ksa
Kbt
Ksb
Tank
Pump
Check Valve x
Powered Extension Mode
Regeneration flow can be defined as pumping the fluid from
one chamber to the other to achieve motion control of the load
with using no or minimum flow from the pump.

41. Power Savings Traditional Valve Independent MeteringQ
Losses on Input Valve
Useful Power
Losses on Output Valve
Saved Power
Traditional Valve
Independent Metering
Valve Configuration
Saved Power

42. Regenerative Modes versus Powered Modes
HSRE vs PE
Ps, Qs a b
High Side Regeneration
Extension
Pr, Qr
Powered

43. Using High Side Regeneration Extension
HSRE vs PE
Using Powered Extension
With High Pump Pressure
Using High Side Regeneration Extension
Saves Pump Flow
Used Power
Lost Power
Saved Power Q P

44. LSRE vs PE Using Powered Extension With High Pump Pressure
Using Low Side Regeneration Extension
Saves Pump Flow and Pressure
Used Power
Lost Power
Saved Power Q P

45. Vibration Analysis
Effect of Mode Switching

46. Vibration Analysis
Telehandler Boom

47. Continuously Variable Modes (CVMs)
Three-Valve Modulation Modes
Use three valves to provide the fluid flow path instead of two valves
Better force-speed capability and better velocity performance

48. Continuously Variable Modes (CVMs)
PHSRE
Pump
Ksa
Ksb
Cylinder Ps qb qa
Kbt
Tank Pr

49. Continuously Variable Modes (CVMs)
Pump
Ksa
Kbt
Tank
Cylinder Ps Pr qb qa
Kat
qout
qin
Check Valve Ps Pr
Kat
Ksa a b q1 q2 q3
Kbt
PLSRE

50. Continuously Variable Modes (CVMs)Pr Ps
Ksb
Kbt
Kat a b q2 qb q1 q3
Kat
Kbt
Tank
Cylinder Pr
qout
qin
Pump
Ksb Ps qa qb
PLSRR

51. Experimental Validation of CVM concept using PLSRE mode
Bucket
Boom
A typical Tractor Loader Backhoe (TLB)
Crowd

52. Experimental Validation
Free Air Motion: Controller I: All in PE
Energy Consumed:
653.8 KJ

53. Experimental Validation
Free Air Motion: Controller IV: PLSRE CVM
Energy Consumed: KJ

54. Experimental Validation
Free Air Motion: Summary
Controller
Velocity Performance
Energy Consumed
All in PE
Acceptable
653.8 KJ
Abrupt Transition
Not- Acceptable
135.1 KJ
Linear Transition
129.1 KJ
PLSRE CVM
Very Good KJ