EXP.

2: HYDRAULIC SERVO SYSTEM

2.1. Introduction to the Hydraulic Servo Model

2.1.1 A general introduction of the experimental model

A general introduction of the experimental model is shown in Figure 2.1

Fig 2.1: Mobile laboratory kit

2.1.2 Construction and Function of Linear Drive Module

Fig 2.2: Linear hydraulic drive module

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 Construction of Linear Drive

Fig 2.3: A diagram of linear hydraulic drive module

The linear drive (in Figure 2.3) consists of the following components:

A slide (1)
A double-acting cylinder (2)
Two guiding rods (3)
Two yokes (4)
Two hydraulic quick connection couplings (5)
A scale (6)
Displacement encoder (7).

Function of the Linear Drive:

The cylinder chambers are pressurized via the two hydraulic quick
connection couplings.
The chamber pressures and the effective piston surfaces produce a
resulting force, which acts upon the slide.
The traversing speed is determined by the prevailing oil flow rate,
whereby the flow rates vary from the plain piston surface to the piston
rod side.

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 The slide is of low friction running on ball bearing guides.
The displacement encoder has been fitted underneath the slide next to
the hydraulic cylinder and is thus largely protected from damage.
A scale has been attached to the mounting brackets for visual
measurement of position.
This can be adjusted slightly towards the mounting bracket.

Construction and connection of the displacement encoder

Fig 2.4: Construction and connection of the displacement encoder

a) Potentiometer f) Housing
b) Pin assignment g) Supply voltage
c) Plug h) + Signal
d) Reference voltage source i) Signal
e) Impedance converter j) Supply earth

Function of displacement encoder

The potentiometer is supplied with 10 V from a reference voltage source located in

the supply line. The voltage tapped via the follower is proportional to the distance
travelled by the connecting rod.

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 Technical data:

Table 2.1: Technical data of hydraulic cylinder

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2.1.3 Construction and Functions of Directional Control Valve

Fig 2.5: A 4 gate/3 position regulating valve

Construction of directional control valve

The directional control valve (shown in Figure 2.6) consists of the following
components:
Plug screw for zero setting (1)
Extension plug (2)
Control sleeve (3)
Control socket (4)
Integrated electronics (5)
Position encoder (6)
Linear motor (7)
Reset spring (8)
Plug (9)

Fig 2.6: Cross section of 4 gate /3 position regulating valve

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 Function of Directional Control Valve

An electrical control signal (in effect a control piston set-point position value,
but subsequently referred to as a set-point volumetric flow rate value) is output
to the integrated position controller, which drives the linear motor via the
pulse-width modulated (PWM) driver electronics.
The position encoder supplied via an oscillator measures the position of the
control piston.
This actual value signal is rectified via a demodulator, returned to the position
controller and compared with the set-point value.
The position controller now activates the linear motor until the set-point and
actual value are the same, whereby the position of the control piston is
proportional to the electrical input signal.
The actual flow rate q is, however, not only dependent on this electrical input
signal, but also critically depends on the pressure drop at individual control
edges.
Construction of Linear Motor

The linear motor (shown in Figure 2.7) is constructed by the following components

Cable through hole (1)

Permanent magnets (2)
Reset springs (3)

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 Bearing (4)
Coil (5)
Armature (6)
Plug screw (7)

Fig 2.7: Linear motor

Function of Linear Motor

The linear motor is a differential motor energized via a permanent magnet.
This means that part of the required magnetic force is already built-in.
As a result of this, the current requirement of the linear motor is significantly
less than that of comparable proportional magnets.
The linear motor has a neutral mid-position and from this position is able to
generate strokes and forces in both directions.
These are proportional to the flow.
Proportional solenoid systems, however require either two proportional
solenoids with correspondingly complex wiring or operate unilaterally against

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 a spring, whereby a reliable spring setting can only be achieved by means of
over-travelling a power port (A or B).
This can lead to uncontrollable movements on the drive unit.
The linear motor does not draw any current in the spring centered position (mid
or out of trim position).
The high spring rigidity and the resulting reset force is overcome when
advancing from the mid-position as are external forces, in-creased frictional
forces due to contamination of the piston spool).
When returning in the direction of zero position, the spring force is combined
with the motor force, i.e. maximum force is always available when the piston
spool closes.

Static characteristics

Fig 2.8: Control piston/signal characteristic curve

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 Fig 2.9: Pressure/signal characteristic curve

Fig 2.10: Flow rate/differential pressure characteristic curve

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 Fig 2.11: Flow rate/signal characteristic curve

Dynamic characteristics

Fig 2.12: Dynamic characteristics of control valve

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 Pin Assignments

Fig 2.13: Pin assignments

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2.1.4. Construction and Function of a PID Controller

Fig 2.14: Appearance of the PID controller

Design of Controller

The PID controller is made up of the following function areas:

Power supply
Differential inputs
Comparator
Controller components:
Proportional component
Integral component
Differential component
Correcting variable offset
Summation point
Limiter
Output

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 Function

This PID controller can be used as a controller for closed-loop pneumatic and
hydraulic control circuits.

Fig 2.15: PID controller diagram

The PID controller diagram which is shown in the Figure 10 consists of the following
facilities

(1) Power supply + 24 V

(2) Power supply ground 0 V
(3) Sensor power supply + 15 V
(4) Sensor ground or analogue ground
(5) Differential set-point input
(6) Differential actual-value input

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 (7) Comparator
(8) Over-modulation indicator
(9) Test socket Set-point
(10) Test socket Actual value
(11) Test socket System deviation
(12) Test socket Proportional gain
(13) Test socket Integral gain
(14) Test socket Differential gain
(15) Rotary potentiometer P component
(16) Rotary switch P component
(17) Power-on indicator P component
(18) Rotary potentiometer I component
(19) Rotary switch I component
(20) Power-on indicator I component
(21) Rotary potentiometer D component
(22) Rotary switch D component
(23) Power-on indicator D component
(24) Summation point
(25) Rotary potentiometer for correcting variable offset
(26) Range selector switch
(27) Correcting variable output

Power supply

The PID controller requires a power supply of 24 V. This voltage is converted

internally to +/- 15 V and fed to the controller electronics. The voltages are
electrically isolated from each other, i.e. the controller card has two zero
potentials (analogue ground and power-supply ground (0 V)).

Differential inputs

A differential input is provided in each case on the PID controller for the set-
point and actual-value signals. The differential signal can be measured against

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 analogue ground. The differential inputs are fitted with low-pass filters to
suppress interference. Over-modulation of below -10 V or above +10 V is
indicated by LEDs.

Comparator

The comparator is connected in series with the signal inputs and calculates the
system deviation between the set-point and actual value

Controller components

The three controller components (P, I and D components) can be switched on

and off separately, allowing different combinations to be used. The individual
controller parameters are adjusted with the aid of potentiometers and rotary
switches.

Correcting variable offset

The correcting variable offset can be used to impose constant voltages on the
control signal in order, for example, to compensate for the zero-point shift of
actuators.

Correcting-variable limiter

The correcting-variable limiter converts the controller signals to the working

range required by the actuators. Any over-modulation of the output signal is
indicated by an LED.

Output

The correcting variable can be tapped against analogue ground at the output.

Test sockets

Various test sockets allow signal voltages to be measured against analogue

ground.

Setting the coefficients

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 The coefficients KP, KI and KD of the controller
components are the product of the values set on the
rotary potentiometer and rotary switch.

Technical data

Table 2.2: Technical data of PID controller

2.1.5 Comparator card

Fig 2.16: Display comparative module

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 Key to operator facilities

As shown in Figure 2.16, the module consists of

(1) Power supply +24 V DC

(2) Power supply 0 V
(3) Input A: input voltage 0 10 V
(4) Input B: input voltage 0 10 V
(5) Output contacts A1, A2
(6) Output contacts B1, B2
(7) Adjusting knob
(8) Selector switch
(9) Display

Design
This comparator card has two separate inputs (IN A, IN B), each of which acts
on one of two independent comparators. The outputs of these are designated
OUT A1, A2 and OUT B1, B2. The activation of outputs is shown by LEDs.
The following values can be set on each comparator:
Set-point voltage: -10 V ... +10 V,
Hysteresis (switching difference): 0 V ... 5 V.
The switch-on and switch-off values are defined as follows:
Switch-on value = Set-point + hysteresis,
Switch-off value = Set-point hysteresis
The set-points and hysteresis values are selected by means of a selector switch.
The settings are made with the aid of an adjusting knob. The contrast of the
LCD is adjustable. The menu guidance system also offers a choice of German
and English language. The power supply for the comparator card is 24 V.

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2.1.6. Pressure Sensor

Fig 2.17: Pressure sensor

Construction

The analogue pressure sensor is screwed into a T connector. It can be equipped with
differing pairs of hydraulic couplings, e. g.:

Leak-proof coupling
Quick coupling socket
Double nipple
Coupling nipple
NG6 Coupling
Sealing coupling
Sealing nipple
The couplings must be securely screwed into the connector. The electrical connection
is established via the 4 mm safety connector plugs fitted to the connecting lead.

A diaphragm inside the pressure sensor is distorted as a result of the measuring

pressure applied. This distortion leads to a change in electrical resistance of the
elements on the membrane (piezo-resistive effect). This resistance change is
electronically converted, temperature compensated and amplified.

Technical Data

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 Table 2.3: Technical data of pressure sensor
2.1.7 Hydraulic power pack

Fig 2.18: Hydraulic power pack

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 Design:
(1) Power supply plug
(2) ON/OFF switch
(3) Tank connection T
(4) Pressure-relief valve
(5) Pressure port P
(6) Tank connection (blue) for reservoir
(7) Pressure gauge
(8) Drain screw
(9) Tank
(10) Sight glass for level indicator
(11) Flange
(12) Capacitor
(13) Electric motor
(14) Tank connection (blue) for discharge

Fig 2.19: Construction and connection of the hydraulic power

Function
The hydraulic power pack converts electrical energy into hydraulic drive
power. The electric motor (13) drives a gear pump (17). The oil is fed from the
tank (9) via the suction pipe (15) and applied at pressure port.

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 The pressure can be read from the pressure gauge (7). The pump delivers a
virtually constant flow rate. The maximum pressure value is set by means of
the pressure relief valve (4). This pressure can only be maintained up to the
maximum delivery rate of the pump.
If the connected hydraulic circuit requires a higher flow rate, the pressure will
fail. The pressure prevailing at this point adapts itself to the flow resistance of
the connected circuit, whereby the flow rate e.g. on a pump by-pass circuit,
return at low pressure.
The return flow is affected via the tank connection T (3) through the return
filter (16) into the tank (9). A blue quick coupling socket (14) has been
provided for the return flow from the pressure reservoir. The filling level can
be read from the sight glass (10). The return flow from the discharge
measurement tank is routed through connection (6).

Technical data

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 Table 2.4: Technical data of the hydraulic power pack

2.1.8 Tubing line with quick connection coupling

Fig 2.20: Tubing line

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 The high-pressure tube consists of three layers. The inner layer is made from
polyamide, the second layer from wire mesh and the top layer from
polyurethane. The two quick coupling sockets are self-sealing when decoupled.
Coupling takes place by pressing the quick coupling socket onto the nipple
until the locking sleeve engages.
Decoupling takes place by retracting the sliding sleeve. The quick coupling
socket is released from the nipple. During the coupling process, only the face
of the coupling is coated with oil.

Technical data
Length: 300, 1000, 1500, 3000mm.
Operating pressure 6 MPa (60 bar)
Max. Permissible pressure 12 MPa (120 bar)
Temperature range: -40 - + 125 C
DN 06 ( 6,3 mm)

2.2 PCI Card 6052E

2.2.1 Introduction

Fig 2.20: Appearance of PCI 6052E

The NI 6052E is a high-performance multifunction analog, digital, and timing I/O

device for PCI, PXI, or 1394 bus computers. Supported functions include analog input
(AI), analog output (AO), digital I/O (DIO), and timing I/O (TIO).
The device has the following features:

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 Two 16-bit A/D converters (ADCs) with 16 analog inputs
16-bit D/A converters (DACs) with voltage outputs
Eight lines of transistor-transistor logic (TTL)-compatible DIO
Two 24-bit counter/timers for TIO

2.2.2 Hardware overview

Fig 2.20: The hardware block diagram

Analog Input
The AI section of the NI 6052E is software configurable. You can select different AI
configurations through application software designed to control the device. The
following sections describe the types of AI configurations.
Input mode
The NI 6052E has three input modes: non-referenced single-ended (NRSE) mode,
referenced single-ended (RSE) input mode, and differential (DIFF) mode. Input
modes are programmed on a per channel basis for multiple modes scanning. For

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example, you can configure the circuitry to scan 12 channelsfour differentially
configured channels and eight single-ended channels
Input Polarity and Input Range
The NI 6052E has two input polaritiesunipolar and bipolar:
Unipolar input polarity means that the input voltage range is between 0 and
Vref ,where Vref is a positive reference voltage.
Bipolar input polarity means that the input voltage range is between Vref/2
and +Vref /2. The device has a unipolar input range of 10 V (0 to 10 V) and
a bipolar input range of 10 V (5 V).
You can program polarity and range settings a per channel basis so that you can
uniquely configure each input channel.

Fig 2.21: The input range of analog input channels

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 Pin Assignment

Fig 2.22: I/O connector pin assignments

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 Specifications:
Analog input:
Number of channels: 16 single-ended or 8 differential (software-
selectable per channel)
Type of A/D converter (ADC): successive approximation
Resolution: 16 bits
Max sampling rate: 333 kS/s
Analog output:
Number of channels: 2 voltages
Resolution: 16 bits
Max update rate: 333 kS/s
Type of D/A converter (DAC): Double-buffered, multiplying
FIFO buffer size: 2048 samples.
Data transfer: DMA, interrupts, programmed I/O
Digital I/O:
Number of channels: 8 input/output
Compatibility: 5V TTL/CMOS
Power-on state: Input (high-impedance)
Timing I/O:
Number of channels: 2 up/down counter/timers, 1 frequency scaler
Resolution: Counter/timer: 24 bits; frequency scaler: 4 bits
Compatibility: 5V TTL/CMOS
Base clock available: - up/down counter/timers: 20 Mhz, 100KHz
- Frequency scaler: 10 Mhz, 100KHz
Base clock accuracy: 0.01%
Max external source frequency: 20Mhz

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2.3 PID controller

Fig 2.23: Matlab Simulink for position control

Type KP KI KD

P 0,5Kcrit - -

PI 0,45Kcrit 1,2Kcrit /Tcrit -

PID 0,6Kcrit 2Kcrit /Tcrit Kcrit .Tcrit/8

Table 2.5: Determine the PID parameters by Ziegler-Nichols method

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2.4 Experimental Steps

Step 1: Checking all the connections of the system

Fig 2.24: General hardware connections

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 Fig 2.25: Electrical connections

Step 2: Investigate the open loop characteristic

Fig 2.26: Open loop block diagram

Design a Simulink program as follow:

Fig 2.27: a Simulink program for open loop investigation

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 Constant block: change the input voltage applied to the valve
Analog Output: being used to interface with the PCI card, block
parameters as follow

Fig 2.28: Block parameters of analog output

Analog Input: block parameters

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 Fig 2.29: Block parameters of analog input

Note: Before changing a new value, let make the slide table to home position.

Complete the following table:

Voltage (V) 1 2 3 4 5 6 7 8 9 10
Time (t)
Velocity
Voltage (V) -1 -2 -3 -4 -5 -6 -7 -8 -9 -10
Time (t)
Velocity

Drawing a curve describing a relationship between the voltage and time (V-t)

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Step 3: Position control for the slide table

Design a PID program using Simulink-Matlab as the Figure 2.23

Using Ziegler-Nichols 2 method to determine Kp, Ki, Kd parameters
Fine-tuning to get the most suitable parameters for servo control:
Fast response
No overshoot
No oscillation

Fig 2.30: The real servo system

Step 4: Make a report for all the results of the experiment

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