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Actuators
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19 February 2025

Study on the Vibration Characteristics of Separated Armature Assembly in an Electro-Hydraulic Servo Valve Under Interference Fit

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1
Department of Fluid Control and Automation, Harbin Institute of Technology, Harbin 150001, China
2
Training Base of Army Engineering University, Xuzhou 221001, China
3
Qingan Group Co., Ltd., Xi’an 710082, China
*
Authors to whom correspondence should be addressed.
This article belongs to the Special Issue Recent Developments in Precision Actuation Technologies

Abstract

The electro-hydraulic servo valve is a critical component that transforms electrical signals into hydraulic signals, thereby controlling the hydraulic system. It finds extensive application in precision control systems. The stability of the electro-hydraulic servo valve is primarily influenced by the armature assembly. Unlike integral armature assembly, the separated armature assembly, comprising the armature, spring tube, flapper, and feedback spring, is joined through an interference fit, which introduces prestress within the assembly. The existence of prestress may affect the operational mode of the armature assembly. Consequently, this paper investigates the vibration characteristics of the separated armature assembly under interference fit conditions. Comparative analysis reveals that interference fit indeed generates prestress, which cannot be overlooked. To further validate the reliability of the simulation results, the natural frequency of the separated armature assembly is determined by applying a sweeping frequency signal to the torque motor using an electric drive, thereby verifying the feasibility of the simulation analysis. Additionally, the impact of interference on the vibration characteristics of the separated armature assembly is examined, confirming the accuracy of the simulation analysis method based on the interference fit. The research on vibration characteristics of a separated armature assembly provides technical support for the structural optimization design of the electro-hydraulic servo valve, thereby enhancing its performance.

1. Introduction

The nozzle flapper servo valve has the advantages of fast response, high precision, and high sensitivity, and is widely used in hydraulic servo control systems. The occasional whistling during the operation of the servo valve [1], causes the spring tube rupture, resulting in servo valve failure, and even affects the function of the hydraulic system. The whistling is caused by the phenomenon of self-excited oscillations. The reported research shows that the self-excited oscillations are not only related to the pressure pulsation of the pilot-stage flow field [2,3] but also to the vibration characteristics of the armature assembly [4].
Mode is the inherent vibration characteristic of the structure, so the mode of the armature assembly is studied in this paper. As shown in Figure 1, the separated armature assembly is composed of four parts: armature, spring tube, flapper, and feedback spring. The characteristic of the separated armature assembly is that the flapper and feedback spring are two independent parts, while in the integral armature assembly, the flapper and feedback spring are integrated. Many researchers have studied the modal analysis of components. Zhang [5] used a modified transfer matrix method to calculate the modal calculation of the rotor in the turbomolecular pump, and the experiment proved that the method could calculate the modal of the rotor assembly with high accuracy. Kim [6] carried out natural frequency and Campbell diagram analysis of the turbine blades according to their assembly conditions, and verified the modal characteristics and resonance stability. Zhai [7] calculated the natural frequency and mode shape of the rotor assembly without a thrust disk through the transfer matrix method according to the actual assembly relationship, and verified the results by using the finite element method and a new modal experiment method, the interference fit and clearance fit between the parts were also considered in FEM. Daouk [8] studied the relationship between the number of bolts, the position of the bolts, and the pre-loaded torque value on the modal damping of the assembly. Yang [9] conducted modal analysis experiments using the force hammer excitation method and obtained the natural frequency and modal modes of stacked chip components.
The modal analysis of components cannot be simplified in some cases, and the influence of external conditions on the stiffness needs to be considered [10,11,12]. Orlowska [13] studied the effect of prestress on the natural frequency and dynamic characteristics of eccentric prestressed glass fiber reinforced polymer composite beams. The results show that prestress increases the first bending frequency and decreases the second bending frequency, and a comparison of the numerical and experimental data confirmed this effect. Hu [14] studied the effect of prestress on the dynamic characteristics of rail transit gearboxes and compared it with the model without prestress; the results showed that prestress has a significant effect on the modal characteristics of the gearbox. Through finite element analysis, Wang [15] constructed a prestressed modal module to obtain the strength and modal characteristics of the steering device. Li [16] studied the sealing interface of the ultra-high pressure diaphragm compressor cylinder head, and found that some modal frequencies changed transition with bolt loosening. Liu [17] analyzed the dynamic behavior of the printed circuit board assembly (PCBA) and the reliability of the board-level solder joints under thermal–vibration combined load. The results showed that when the temperature changes from 22 °C to 60 °C, the natural frequencies of PCBA decreases, resulting in a decrease in the fatigue life of solder joints. Therefore, in some cases, external conditions have an effect on the dynamic characteristics of components.
Different from the general components, the separated armature assembly is composed of four parts connected by interference fit. Interference fit usually occurs under the condition of shaft and hole fit, and the magnitude of interference has an effect on the modes of the components [18,19]. Fan [20] used Ansys Workbench software to study and analyze the modes of the rotor assembly connected by the interference fit between the elastic shaft and the rigid thick disk and obtained the natural frequency of the component.
In this paper, in order to explore the vibration characteristics of the separated armature assembly and provide technical support for the structural design and optimization of the servo valve, the influence of bonded, friction contact type, and contact surface nodes coupling or not on the modes of armature assembly is studied, and the influence of interference on the modes of armature assembly is further studied.

2. Armature Assembly

2.1. Geometry Model of Armature Assembly

There are two types of armature assembly: integral and separated, the separated armature assembly is composed of four parts: armature, spring tube, flapper, and feedback spring, and the four parts are assembled together by interference fit. As shown in Figure 1, armature and spring tube interference assembly, spring tube and flapper interference assembly, flapper, and feedback spring interference assembly. Therefore, there is prestress in the armature assembly under normal working conditions. The research shows that the existence of prestress has an effect on the modes of the structure [13,14,15].
Figure 1. Separated armature assembly.

2.2. Dynamic Model of Armature Assembly Under Prestressed Condition

For armature assembly, the free vibration differential equation without damping can be described as follows [21]:
[ M ] { u ¨ } + [ K ] { u } = { 0 }
where [ M ] is the mass matrix of the armature assembly, [ K ] is the stiffness matrix of the armature assembly, { u ¨ } is the vibration acceleration matrix, and { u } is the displacement matrix.
Under certain initial conditions, armature assembly move at the same frequency according to simple harmonic vibration.
{ u } = { ϕ } sin ( ω t + θ )
Then, the equation can be simplified as
( [ K ] ω i 2 [ M ] ) { ϕ i } = 0
ω i 2 = { ϕ i } T [ K ] { ϕ i } { ϕ i } T [ M ] { ϕ i }
where { ϕ i } and ω i are modal shape and natural frequency of the ith mode, respectively.
Due to the interference fit of the armature assembly, the assembly prestress [ σ ] is generated, which generates a stress stiffness matrix [ S ] . The stress stiffness effect can be realized by superimposing the stress stiffness matrix into the elastic stiffness matrix of the structure.
[ K s ] = [ K ] + [ S ]
where [ S ] represents the stress stiffness matrix that accounts for assembly prestress, [ K s ] represents the stiffness matrix of the armature assembly considering the assembly prestress. This result is derived by substituting Equation (5) into Equation (3).
( [ K s ] ω i s 2 [ M ] ) { ϕ i } = 0
ω i s 2 = { ϕ i } T [ K s ] { ϕ i } { ϕ i } T [ M ] { ϕ i }
where ω i s is the natural frequency of the ith mode considering the assembly prestress.
Thus, the ω i s can be described as
ω s 2 = ω i 2 + { ϕ i } T [ S ] { ϕ i } { ϕ i } T [ M ] { ϕ i }

5. Precautions for the Design of Servo Valves

In the case of either integral or separated armature assembly, the mechanism of self-excited oscillation is similar. The natural frequency of the armature assembly is coupled with the pressure pulsation in the pilot stage flow field. The problem of internal stress caused by the interference fit of the separated armature assembly is relatively prominent, which cannot be simplified as the integral armature assembly.
The stiffness of the armature assembly is critical to the function and performance of the servo valve and must be prioritized as the primary consideration. In terms of vibration characteristics, the vibration source is mainly the pressure pulsation of the pilot valve, it is recommended to adopt the following schemes to reduce the probability of self-excited oscillation of the servo valve.
(1)
For a separated armature assembly, while ensuring compliance with the assembly’s stiffness requirements, the natural frequency of the armature assembly can be altered by modifying the structure or adjusting the interference fit.
(2)
While ensuring the fundamental functionality of the pilot stage of the servo valve, it is possible to modify the flow field structure to alter the frequency and amplitude of pressure pulsations. This adjustment helps to prevent the coupling of the pressure pulsation frequency with the natural frequency of the armature assembly, thereby reducing the likelihood of self-excited oscillations in the servo valve and enhancing its overall performance.

6. Conclusions

In this paper, the vibration characteristics of the separated armature assembly based on the interference fit are studied. Four different simulation methods are used to analyze the modes of the armature assembly, and the feasibility of the simulation analysis is verified by experiments. The following conclusions were obtained:
(1)
Due to the interference connection between the parts of the separated armature assembly, prestress is present and cannot be ignored. The method of bonded contact simplification in modal simulation analysis is unscientific. Whether the contact surface has common nodes or not has little influence on the modal simulation results.
(2)
The electric drive method is used to provide sweeping frequency signals to the armature assembly, and the natural frequencies of first-order and fourth-order modes of the armature assembly are obtained by the resonance principle, which verifies the feasibility of the simulation.
(3)
Interference has an effect on the modes of the armature assembly. With the increase in interference, the natural frequency corresponding to the first, third, and fourth modes of the armature assembly, all decrease with increasing interference, but the change is little, while the natural frequency corresponding to the second mode gradually decreases.
(4)
In the design of a servo valve with a separable armature assembly, while ensuring the fundamental functionality of the servo valve, it is possible to enhance its performance through two approaches. On the one hand, the natural frequency of the armature assembly can be modified by altering its structure or adjusting the interference fit. On the other hand, the frequency and amplitude of pressure pulsations can be changed by modifying the flow field structure. These adjustments help to prevent the coupling of the pressure pulsation frequency with the natural frequency of the armature assembly, thereby reducing the likelihood of self-excited oscillations in the servo valve and improving its overall performance.

Author Contributions

Conceptualization, T.L., S.L., J.Z. and A.Z.; methodology, software, writing—original draft preparation, T.L. and S.L.; formal analysis, J.P.; investigation, T.L.; resources, A.Z.; writing—review and editing, J.P. and J.Z.; supervision, J.P. All authors have read and agreed to the published version of the manuscript.

Funding

This research was funded by NSFC, grant number 51675119.

Data Availability Statement

The data presented in this study are available on request from the corresponding author.

Conflicts of Interest

Aiying Zhang is employed by the company Qingan Group Co., Ltd. The remaining authors declare that the research was conducted in the absence of any commercial or financial relationships that could be construed as a potential conflict of interest.

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