Scientific Bulletin of the Politehnica University of Timisoara Transactions on Mechanics Special issue

The 6th International Conference on Hydraulic Machinery and Hydrodynamics Timisoara, Romania, October 21 - 22, 2004

EXPERIMENTAL RESEARCHES UPON STATIC AND DYNAMIC BEHAVIOR OF ELECTRO-HYDRAULIC SERVO VALVES
Victor BALASOIU*, Professor, Department of Hydraulic Machinery Politehnica University of Timisoara Ilare BORDEASU, Assoc. Prof. Department of Hydraulic Machinery Politehnica University of Timisoara Mircea O. POPOVICIU, Professor, Department of Hydraulic Machinery Politehnica University of Timisoara Vergil CHIAC, Senior Lecturer, Naval Academy Mircea cel Btrn Constana

*Corresponding author: Bv Mihai Viteazu 1, 300222, Timisoara, Romania Tel.: (+40) 256 403680, Fax: (+40) 256 403682, Email: balasoiu@mec.utt.ro; mpopoviciu@mec.utt.ro ABSTRACT Electro-hydraulic servo valves as interfaces in automatic hydraulic systems are forced to meet demands regarding the static and dynamic behavior, to be reliable and easy to maintain. As a result, it is necessary that separately from the mathematical simulation (which were previously carried out), to put servo valve to experimental test, in facilities well-equipped and able to evidence the influence of various parameters upon the working performances. These facilities must afford to carry out tests in static and dynamic conditions both for the control stage (of flap-nozzle type) and the whole directional control valve. Te paper presents the facility for experimental researches designed and manufactured in Timisoara Laboratory for Hydraulic and Pneumatic Drive Units. There are also presented the hydraulic components of the facility together with the electronic devices for data acquisition and treatment. After presenting the facility parameters, the restrictions regarding the operational conditions are emphasized. It is presented also the experimental researches program, the calibration methodologies for the measuring devices and the calibrations characteristic curves. The tests were carried out for the following parameters: constant input pressures p0 (which was parametrically modified in four steps between 4.0 and 10.0), control electric currents iC = (015) mA and flow capacities QM = (1020) l / min. The experimental researches confirm the previous mathematical simulation adopted for static and dynamic identification of servo valves. KEYWORDS Electro-hydraulic servo valves, experimental researches, static and dynamic behavior. 1. INTRODUCTION, SYNTHESIS REGARDING THE TESTING METHODS Electro-hydraulic servo valves (EHSV), as interface elements are compelled to meet demands regarding the static and dynamic behavior, to be reliable and easy to maintain. As a result, it is necessary, that in parallel with the mathematical simulation, EHSV must be tested in special equipped facilities, where the influence of various parameters upon the running performances must be put into evidence. The experimental research methods were gradually improved in world-famed laboratories [1-4, 5-11,14] by critical analyses of the procedures, the facilities and the measuring apparatuses used. Tests are permanently present in the life of servo valves, both in the faze of experimental models or prototypes when the objective is to improve the constructive an working solutions and in exploitation faze when the stability of the certified parameters are verified. Finally, the experimental research carried out on EHSV must specify their static and dynamic behavior. 2. THE TEST FACILITY AND THE USED EQUIPMENTS The experimental research method on which was built the facility for testing the EHSV in static and dynamic regimes is presented in details in [1, 2, 7]. This facility allows also to carry out tests in static and dynamic conditions both for the control stage (of nozzle/ flap type) and for the directional control valve as a whole. In Fig. 1 is presented the EHSV-2T having spring return in complete mounting, mechanical reaction and positional electrical reaction. The tests were carried 311

out in the flow range Q = 2.530 l / min and at pressures pn = 2.515 MPa [1]. The test facility is shown in Fig. 2 and 3 where are presented also the systems for the quantitative determination of characteristic magnitudes for the experimental model. The facility used for testing in static conditions the EHSV (Fig. 2) is composed of: hydraulic circuit with pressurized oil, rigid and flexible pipes, oil tank, filters and hydraulic accumulator. The throttle valves mounted at the EHSV outlet, on the line connection A, B and R gives the possibility to modify the load of the working circuits. The pressure is maintained constant or adjusted by a pressure valve mounted in the hydraulic circuit. The dynamic condition behavior as response in flow rate is put into evidence by a micro cylinder (Fig. 3) having a piston with negligible mass, reduced inertia and minimum friction force; on its rod was mounted a motion inductive transmitter TD 25. The facility presents the following peculiarities: separate tests in static and dynamic conditions both for the control stage and EHSV as a whole. For response in pressure, the measuring circuit is equipped with pressure inductive transducers connected to the voltage bridges and to a two spots oscilloscope. The measurements of the testing parameters are done with:

the input flow, with a turbine flow measuring device, the range of it being established in correlation with the value of flow capacity; the pressure and the pressure drop, by pressure gauges and inductive pressure transducers with tensoelectronic bridges.

Figure 1. Electro-hydraulic servo valve EHSV-2T 1. control motor; 2. hydraulic potentiometer (nozzle flap); 3. control of distributor; 4. distributor

Figure 2. The facility used for testing EHSV-2T in static condition 312

Figure 3. The facility used for testing in dynamic condition

Figure 9.a

Figure 9.b 313

An electronic program controller assures the EHSV electric control of coils. The electronic block for experimental data measuring, recording and processing include: a double voltage source, low frequency generator, two spots oscilloscope, amplifier and tensoelectronic bridge. For systematic studies of the EHSV basic element, the assembly spool valve / directional cylinder, there have been analyzed eight valve casings, having eight different overlap degrees Y0i in the range (-15 % < Y0i < +15 %) [1]. Before beginning the tests every measuring system was carefully calibrated. 3. STATIONARY AND DYNAMIC BEHAVIOR OF EHSV The experimental researches upon different variants of EHSV-2T have been done with input pressure range p 0 = 4.0; 5.5; 7.0; 10.0 MPa, for control electric currents iC = (0..15 ) mA and flow capacities QM = (1020) l / min, in agreement with the methods presented in [1, 2]. The researches in stationary conditions have in view: a) to determine the adjustment characteristic flow / current at zero load Q M = f ( i C ) p = ct (Fig. 5);
M

Figure 4

b) to determine the static characteristic flow / pressure at constant input current Q M = f (p M )iC = ct ; c) to determine the static characteristic pressure / current for zero flow p M = f (iC )QM =ct for the control stage nozzle/flap (Fig. 4) and the spool valve / direction control body; d) to determine the internal leakage Q SC = f ( i C ). On the basis of the experimental researches there have been obtained the characteristic curves in stationary conditions for the stage nozzle / flap p M = f (iC ) Fig. 4 and for the assembly EHSV-2T
Q M = f (p M

Figure 5a

) and

Q M = f i c , Fig 5a, 5b and 5c.

( )

The static characteristic of the studied experimental models put into evidence the following aspects (Fig.4, Fig. 5a, 5b, 5c): the micro geometry of the control stage nozzle / flap but also of the assembly spool valve / distributor have a quantitative and qualitative influence upon the static characteristics of EHSV, modifying the characteristic parameters: linearity, resolution, hysteresis, symmetry and zero current; the linearity zone of the control pressure (Fig. 4) and of the adjusted flow (Fig. 5) is maintained for wide variation limits of the control current iC, after which appears the supersaturated zone, situation confirmed also by the theoretical researches [1, 2, 5, 7]; 314

Figure 5b

Figure 6 Figure 5c the flow that crosses the ensemble directional control valve such as the zero flow (iC = 0) are greatly affected by the type of overlap Y0i; the linear variation of flow near the zero overlap (Fig. 5b) is altered in the case of positive or negative overlap (fig.5a; 5c) when nonlinearties of the type insensibility zone or jumps may appear; the non linearity of the characteristic curves and consequently the non linear behavior of EHSV is a result of manufacturing tolerances or deviations from the prescribed geometry of the spool valve, more precisely is a result of the overlap degree. For the general presentation of the experimental research results the static characteristic of the tested models were presented in non dimensional form which assure an easy way for comparisons with other directional control valves [1,4]. The tests of EHSV in dynamic conditions have in view the determination of module and faze / frequency characteristics presented through Bode diagrams. The dynamic characteristics are determined in flow and pressure response both for the control stage nozzle / flap and for the directional control valve as a whole, for different values of the working flow capacity for nominal current. The reply characteristic curves attenuation-amplitudefaze-frequency were presented in normalized form 0 H svn dB = f ( Hz ) and hsvn = f ( Hz ) as can be seen in Fig.7 and 8, to facilitate the comparisons between the theoretical results obtained in [1, 4] and those obtained experimentally on models tested at various input pressures (p0 = 4.0; 5.5; 7.0; 10.0 MPa) and control currents (iC = 5.0; 7.5; 10.0 mA) (Fig. 9). From the analyze of these characteristics there were pointed out the following significant aspects: the static and dynamic characteristics of the tested model are presented in a general form and give a unitary image; they give a unitary basis to compare the tested device with other EHSV, manufactured elsewhere; they confirm the hypothesis used for the relations which defines the characteristic parameters in a non dimensional or standardized form; the static and dynamic characteristics in non dimensional and standardized form constitute an important criterion to appreciate the manufacturing quality of EHSV but also the quality of the accomplished experimental researches. Besides the characterization of the static properties, the stationary characteristic curves give also information about the final qualities of the EHSV components. In this direction can be mentioned: the overlap degree, the symmetry of spool valve edges, the deviation from the coaxial position and the eventuality of some linearity deviations. The adjustment characteristic QM = f(ic) indicate the link between the input magnitude iC and the adjusted flow QM for an EHSV connection without load (pM = 0). The function QM = f(iC) obtained for eight overlap degrees offers details about the actual form of overlapping and its influence upon the EHSV performances. The knowledge about the actual overlap (-, 0, +) is extremely important for the determination of pressure variation pM downstream EHSV at a given input pressure p03. A relatively low downstream pressure is the result of small positive overlaps while a high downstream pressure is the result of a radial clearance combined with a negative overlap. 315

Figure 7

Figure 8

Figure 10 316

The determined both theoretic [1, 4] and experimental (Fig. 4, 5) static characteristics, around the zero position of the spool valve, demonstrate that always exist flow leakage, even if they are minimum at a distributor with zero overlap (Fig. 5b). The load characteristic QM = f(pM) give details both upon the static and dynamic behavior of the adjustment circuit. The influence of overlap degree and annular clearance become also evident. Depending on overlap degree the differences between the theoretical and experimental results are greater (58 %) a high values of negative or positive overlaps (Fig. 5a, c) with regard of the zero overlap (Fig. 5b). The greatest differences (410%) occur for the smaller openings (iC = 5.0; 7.5 mA) and not for the nominal opening (iC = 10.0 mA). For the small range openings the differences are produced by the laminar flow, in conformity with the Hagen-Poiseuille law, the viscosity being influenced by temperature, finally affecting the flow coefficient. For the negative overlaps the rigidity is maximum but also the insensibility zone is maximum and the pressure is reduced. For spool valves with zero overlap the rigidity is suitable and the precision is increased but such conditions requires excellent filtration (filtration precision). The present manufacturing conditions do not allow the assurance of the zero overlap. The directional control valves designed for zero overlap are manufactured always with positive or negative overlap, the neighborhood of zero being a function of the possible manufacturing tolerances. The influence of the annular clearance J is well marked for negative overlaps, the phenomenon remaining till in the immediate neighborhood of zero overlap. The flow increase is given both from the leakage in the annular clearance and the negative overlap. The reduced positive or negative overlap degree YOI = (0.0050.03)Y0N bring up the adjustment characteristics of EHSV to the zone with reduced insensibility (Fig. 5b). The reproduction of the characteristics for a new adjustment indicates a good resolution of EHSV. The good agreement of the experimental characteristic curves (Fig. 5a, b, c, Fig.6) with those theoretic obtained [1, 4, 5] both for linear and non linear range, confirm the hypothesis which stood at the basis of the analytical computation method. The differences (3 10 %) resulted from: the dissimilar balance of the springs that centers the spool valve; the manufacturing errors of the micro geometry of the spool valve; the differences of clearances for various cylindrical valves (the limits are 0.0050.007 mm); the experimental

inherent errors; the variation in the temperature of oil, etc. From the analyze of frequency and step signal response diagrams, determined for the stage nozzle / flap and for the entire spool valve (Fig. 710) it result: a good qualitative concordance between the theoretical model defined in [1, 4] and the experimental model from the series EHSV-2T and the model EHSV 4WS-7.5-2EB for EHSV 2T-7.5 the amplitude characteristics phase / frequency at 45 phase difference depends on the control current ensuring a response of = 17 50 Hz (Fig. 8;9;10) the dynamic behavior of EHSV improves with the grows of the input pressure (Fig. 8;9;10); the dynamic behavior of EHSV improves with the growth of the input pressure (Fig. 8;9;10); the dynamic behavior of EHSV2T-7.5 is improving with the increase of the passing flow in the range Q = (2.57.5) l / min, at pressures p = (5.510) MPa and iC = 10 mA having an increased variation of the response frequency for the assembly directional control valve; the response time for a step signal (tr ms) is reduced with the increase of input pressure and the control current until the super saturation of EHSV; - - the absolute value of the response time (tr =1030 ms) confirm the excellent performances of EHSV-2T and the belonging of the valve in the class of rapid hydraulic systems; the frequency characteristics presented in Fig. 8-10 allow to analyse the dynamic behavior of the EHSV at variable frequency. 4. CONCLUSIONS The experimental facility (Fig. 2, 3) allow: the testing at constant values for pressure, control current and flow, without oscillation; the investigation of the same experimental model in a large zone of flows, pressures and control currents; the experimental verification of the hypothesis and the computing relations theoretically established in [1,4]. The experimental researches permitted to determine: the static characteristic curves for eight overlaps degrees, at different input pressures and command currents;

the characteristic curves for frequency and response to a step signal for a large range of control currents, input pressures and flow capacities (Fig. 5-10); the confirmation of a good agreement between the theoretically and experimentally obtained static and dynamic characteristics and as a result the confirmation of the adopted mathematical mode for static and dynamic identification of EHSV. REFERENCES 1. Balasoiu V., (1988), Cercetari teoretice si experimentale asupra sistemelor electrohidraulice tip servovalva-cilindru-sarcina pentru roboti industriali, Teza de doctorat, Institutul Politehnic Traian Vuia Timisoara, 1987. 2. Balasoiu V., Padureanu I., Actionari hidraulice, fundamente teoretice, aplicatii, Ed. Orizonturi Universitare, Timisoara, 2002. 3. Balasoiu V., Echipamente hidraulice de actionare, Ed. Eurostampa, Timisoara, 2001. 4. Balasoiu V., Popoviciu M., Bordeasu Il., Theoretical simulation of static and dynamic behavior of electrohydraulic servovalves, Conf. HMH2004, 5. Deacu L.Tehnica hidraulicii proportionale, Ed. Dacia, Cluj Napoca, 1989 6. Drumea P., (1998), Contributii la analiza si sinteza elementelor si instalatiilor de reglare electrohidraulice, Teza de doctorat, Universitatea Politehnica din Bucuresti, 1998, 7. Faisandier J., Mecanismes Hydrauliques et Pneumatiques, , Dunod Paris, 1999. 8. Ionescu I.,Mares Cr., Servovalve electro- hidraulice, Editura Lux Libris, Brasov 1996, 9. Jones J.C, Developments in design of electrohydraulic control Valves from Their Initial Design Concept to Present day Design and Aplications, Workshop on Proportional and Servovalves, Monash University, Melbourne, Australia, 1997 10. Meritt H., Hydraulic Control Systems, Willey, New York, 1967 11. Murrenhoff H., Trends in Valve Development, Institute for Fluid Power Drives Controls (IFAS), RWTH Aachen, Olhydraulik und Pneumatik, 46, nr.4, 2003, 12. Scheffel G., Test Stand and Experimental Valve for Steadstate and Dynamic Valve Testing, OlhydrauliK und Pneumatik, Vol 21, nr.1,1997 317

13. Thayer William J, Specification standards for Electrohydraulic Flow Control Servovalves, Technical Bulletin, MOOG, 1962 14. Thayer William J, Transfer Functions for MOOG Servovalves, Technical Bulletin, MOOG, 1998, 1965.

15. Vasiliu N, si altii, Mecanica fluidelor si sisteme hidraulice, Ed Tehnica Bucuresti, 1999. 16. *** Prospecte ale firmelor: Dowty, Bosch-Rexroth, Abex, Atos Hydraulic, MOOG

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