Search Results (59)

To address the issue of existing automatic irrigation systems’ excessive reliance on electrical power and communication networks, a one-inlet, four-outlet Hydraulically Actuated Irrigation Control Valve (HAICV) was designed that operates based on water pressure variations. Its hydraulic characteristics and flow field features were investigated through experimental and numerical simulation methods. The results indicated that power–function relationships exist between pressure and flow rate, as well as between flow rate and head loss. The flow coefficient and resistance coefficient were found to range within [77.46, 81.06] and [15.94, 17.46], respectively. Dynamic simulations based on User-Defined Functions (UDF) revealed that during the opening process, the internal pressure of the valve spool remains high, with the primary pressure drop concentrated in the outlet region, and the low-pressure zone shrinks as the opening degree increases. A high-velocity band forms at the outlet, with jet flow and turbulence observed at small to medium openings, while the flow field stabilizes after full opening. The unique spool shape and non-straight flow passage structure of the HAICV result in relatively high energy loss, making it suitable for self-pressure irrigation systems. This study provides a theoretical foundation for evaluating its performance and broader applications. Full article

The hydraulic directional valve represents a fundamental component of a hydraulic system. The severe operating environment could cause undesirable faults, with the spool stick being the particular concern. It will lead to a reduction in the overall performance of the operating system, even with the potential for failure. To address this issue, this study presents a hybrid intelligent algorithm-based diagnostic approach for the hydraulic directional valve spool stick fault to facilitate timely industrial inspection and maintenance. Firstly, the monitoring signals on hydraulic directional valves are denoised using wavelet packet denoising (WPD). Then, the denoised signals are decomposed via sparrow search algorithm (SSA) optimized for variational mode decomposition (VMD) in order to obtain a typical fault feature vector. Finally, a combined model of the convolutional neural network (CNN) and the long short-term memory (LSTM) is employed to diagnose the valve spool stick fault. The results of this study indicate that the proposed approach can reduce the signal processing time by 56.60%. The diagnostic accuracy of the approach is 97.01% and 96.24% for sensors located at different positions, and the accuracy of the fusion sensor group is 99.55%. These fault diagnostic performances provide a basis for further research into hydraulic directional valve spool stick fault and are appliable to other hydraulic equipment fault diagnosis applications. Full article

This article is devoted to the design of a real-time gain scheduling (adaptive) proportional–integral (PI) controller for the displacement volume regulation of a swash plate-type axial piston pump. The pump is intended for open circuit hydraulic drive applications without “secondary control”. In this type of pump, the displacement volume depends on the swash plate swivel angle. The swash plate is actuated by a hydraulic-driven mechanism. The classical control device is a hydro-mechanical type, which can realize different control laws (by pressure, flow rate, or power). In the present development, it is replaced by an electro-hydraulic proportional spool valve, which controls the swash plate-actuating mechanism. The designed digital gain scheduling controller evaluates control signal values applied to the proportional valve. The digital controller is based on the new linear parameter-varying mathematical model. This model is estimated and validated from experimental data for various loading modes by an identification procedure. The controller is implemented by a rapid prototyping system, and various real-time loading experiments are performed. The obtained results with the gain scheduling PI controller are compared with those obtained by other classical PI controllers. The developed control system achieves appropriate control performance for a wide working mode of the axial piston pump. The comparison analyses of the experimental results showed the advantages of the adaptive PI controller and confirmed the possibility for its implementation in a real-time control system of different types of variable displacement pumps. Full article

Electro-hydraulic proportional multi-way valves are widely used in construction machinery and equipment, and their performance directly affects the operation performance of construction machinery and equipment. In this paper, an electro-hydraulic proportional multi-way valve was taken as the research object, and the precise control of the position of the spool of electro-hydraulic proportional multi-way valves under multi-source disturbances was studied. A mathematical model of the electro-hydraulic proportional multi-way valve was established to analyze the influence of hardware controller parameters on the control current. A proportional multi-way valve expansion state observer was established to observe the changes in internal and external multi-source disturbances, and a sliding mode controller was used to compensate for the influence of these disturbances on the position control accuracy of the valve spool of proportional multi-way valves. Compared with the PID control method, the results show that, when using the control method proposed in this paper, the reduction in the step response time and improvement in pressure control accuracy for the pilot proportional reducing pressure valve were maximally 44.4% and 0.61%, respectively; the reduction in the step response time and improvement in control accuracy for the spool of the pilot proportional multi-way valve were maximally 69.48% and 61.74%, respectively. The research results in this paper can help to improve the performance and multi-condition adaptability of electro-hydraulic proportional multi-way valves. Full article

This paper presents some of the most significant findings in the design of a hydraulic servomechanism for flight controls, which were primarily achieved by the first author during his activity in an aviation institute. These results are grouped into four main topics. The first one outlines a classical theory, from the 1950s–1970s, of the analysis of nonlinear automatic systems and namely the issue of absolute stability. The uninformed public may be misled by the adjective “absolute”. This is not a “maximalist” solution of stability but rather highlights in the system of equations a nonlinear function that describes, for the case of hydraulic servomechanisms, the flow-control dependence in the distributor spool. This function is odd, and it is therefore located in quadrants 1 and 3. The decision regarding stability is made within the so-called Lurie problem and is materialized by a matrix inequality, called the Lefschetz condition, which must be satisfied by the parameters of the electrohydraulic servomechanism and also by the components of the control feedback vector. Another approach starts from a classical theorem of V. M. Popov, extended in a stochastic framework by T. Morozan and I. Ursu, which ends with the description of the local and global spool valve flow-control characteristics that ensure stability in the large with respect to bounded perturbations for the mechano-hydraulic servomechanism. We add that a conjecture regarding the more pronounced flexibility of mathematical models in relation to mathematical instruments (theories) was used. Furthermore, the second topic concerns, the importance of the impedance characteristic of the mechano-hydraulic servomechanism in preventing flutter of the flight controls is emphasized. Impedance, also called dynamic stiffness, is defined as the ratio, in a dynamic regime, between the output exerted force (at the actuator rod of the servomechanism) and the displacement induced by this force under the assumption of a blocked input. It is demonstrated in the paper that there are two forms of the impedance function: one that favors the appearance of flutter and another that allows for flutter damping. It is interesting to note that these theoretical considerations were established in the institute’s reports some time before their introduction in the Aviation Regulation AvP.970. However, it was precisely the absence of the impedance criterion in the regulation at the appropriate time that ultimately led, by chance or not, to a disaster: the crash of a prototype due to tailplane flutter. A third topic shows how an important problem in the theory of automatic systems of the 1970s–1980s, namely the robust synthesis of the servomechanism, is formulated, applied and solved in the case of an electrohydraulic servomechanism. In general, the solution of a robust servomechanism problem consists of two distinct components: a servo-compensator, in fact an internal model of the exogenous dynamics, and a stabilizing compensator. These components are adapted in the case of an electrohydraulic servomechanism. In addition to the classical case mentioned above, a synthesis problem of an anti-windup (anti-saturation) compensator is formulated and solved. The fourth topic, and the last one presented in detail, is the synthesis of a fuzzy supervised neurocontrol (FSNC) for the position tracking of an electrohydraulic servomechanism, with experimental validation, in the laboratory, of this control law. The neurocontrol module is designed using a single-layered perceptron architecture. Neurocontrol is in principle optimal, but it is not free from saturation. To this end, in order to counteract saturation, a Mamdani-type fuzzy logic was developed, which takes control when neurocontrol has saturated. It returns to neurocontrol when it returns to normal, respectively, when saturation is eliminated. What distinguishes this FSNC law is its simplicity and efficiency and especially the fact that against quite a few opponents in the field, it still works very well on quite complicated physical systems. Finally, a brief section reviews some recent works by the authors, in which current approaches to hydraulic servomechanisms are presented: the backstepping control synthesis technique, input delay treated with Lyapunov–Krasovskii functionals, and critical stability treated with Lyapunov–Malkin theory. Full article

Fuel electro-hydraulic servo valves are core components in the fuel control system of aero-engines, and their performance directly affects thrust regulation and power output precision. Due to the combustibility of the working medium in fuel systems and the lack of effective circulation filtration, the retention of micron-sized particles within the valve gap can lead to valve spool jamming, which is a critical reliability issue. This study, based on fractal theory and the liquid–solid two-phase flow model, proposes a parametric model for non-ideal surface valve gaps and analyzes the dynamics of particles subjected to drag, lift, and buoyant forces on rough surfaces. By numerically analyzing flow field models with different roughness levels and comparing them with an ideal smooth gap model, the migration characteristics of particles were studied. To verify the accuracy of the model, an upscaled experimental setup was built based on similarity theory, and PIV experiments were conducted for validation. Experimental results show that the particle release position and valve surface roughness significantly affect particle migration time. The weight of the release position on particle migration time is 63%, while the impact of valve surface roughness is 37%. In models with different roughness levels, the particle migration time increases more rapidly for roughness values greater than Ra0.4, while for values less than Ra0.4, the increase in migration time is slower. Furthermore, the study reveals that particle migration trajectories are independent of flow velocity, with velocity only affecting particle migration time. This research provides theoretical support for enhancing the reliability of fuel electro-hydraulic servo valves and offers a new perspective for the design of highly reliable hydraulic components. Full article

The body roll of the tractor propagates through its rigid hitch system to the mounted implement, causing asymmetrical soil penetration depths between the implement’s lateral working elements, which affects the operational effectiveness of the implement. To address this issue, this study developed an automatic leveling system based on a dual closed-loop fuzzy Proportional-Integral-Derivative (PID) algorithm for tractor-mounted implements. The system employed an attitude angle sensor to detect implement posture in real time and utilized two double-acting hydraulic cylinders to provide a compensating torque for the implement that is opposite to the direction of the body’s roll. The relationship model between the implement’s roll angle and the actuator’s response time was established. The controller performed implement leveling by regulating the spool position and holding time of the solenoid directional valve. Simulink simulations showed that under the control of the dual closed-loop fuzzy PID algorithm, the implement’s roll angle adjusted from 10° to 0° in 1.72 s, which was 56.89% shorter than the time required by the fuzzy PID algorithm, with almost no overshoot. This demonstrates that the dual closed-loop fuzzy PID algorithm outperforms the traditional fuzzy PID algorithm. Static tests showed the system adjusted the implement roll angle from ±10° to 0° within 1.3 s. Field experiments demonstrated that the automatic leveling system achieved a maximum absolute error (MaxAE) of 0.91°, a mean absolute error (MAE) of 0.19°, and a root mean square error (RMSE) of 0.28°, with errors within 0.5° for 92.52% of the time. Results from terrain mutation tests indicate that under a sudden 5° vehicle roll angle change, the system confines implement deviation to ±1.5°. The system exhibits high control precision, stability, and robustness, fulfilling the demands of tractor-mounted implement leveling. Full article

To improve the dynamic response, linearity, and control accuracy of the YYSCT-250-3 tractor multi-circuit hydraulic output power tester, this study develops a particle swarm optimization (PSO)-tuned fuzzy-proportional–integral–derivative (Fuzzy-PID) control strategy. By modulating the actuator-driven ball valve’s rotation angle (0–90°) in the proportional flow valve, the controller uses both the flow rate error and its rate of change between the setpoint and the flow meter feedback as fuzzy inputs to adjust the PID outputs. A detailed mathematical model of the electro-hydraulic proportional flow system is established, incorporating hydraulic resistance torque on the ball valve spool and friction coefficients to enhance accuracy. Through MATLAB/Simulink (R2022a) simulations, the PSO algorithm optimizes the fuzzy membership functions and PID gains, yielding faster response, reduced overshoot, and minimal steady-state error. The optimized controller achieved relative steady-state flow errors within ±1.0% and absolute flow control errors within ±0.5 L/min, significantly outperforming the traditional PID controller. These results demonstrate that the PSO-optimized Fuzzy-PID approach effectively addresses the flow control challenges of the YYSCT-250-3, enhancing both testing efficiency and precision. This work provides a robust theoretical framework and practical reference for rapid, high-precision flow control in multi-channel hydraulic power testing. Full article

This paper presents a quasi-static model for assessing potential energy savings through partial electrification of a land leveler implement. The quasi-static model simulates the behavior of the hydraulic circuit components, including the pump and a spool-type flow divider, for a commercial land leveler used in agricultural applications. Two electrification schemes are presented. In the first scheme, the pump, originally driven at fixed speed by the PTO, is driven at variable speed by an electric drive, with no changes in the hydraulic circuit. In the second electrification scheme, the decentralization of the hydraulic system is implemented by using separate variable-speed pumps for each actuator. Results show significant potential energy savings of 9–22% with the first electrification scheme and 45–53% with the second scheme, compared to the traditional non-electrified setup. Our findings demonstrate that electrification could be a strategic choice to improve the efficiency of tractor implements and agricultural machinery. Full article

In the development trend of intelligent and high-performance construction machinery, the dual-spool electro-hydraulic valve, as a new-generation core control element, directly affects the operation accuracy and energy-efficiency level of construction machinery. The standard linear extended state observer (LESO) produces relatively serious peaks as the system order increases, which leads to the degradation of the observer’s performance and affects the controller’s accuracy. To solve this problem, this paper innovatively proposes an output feedback control strategy for a cascaded structure observer for the dual-spool electro-hydraulic valve. This paper designs an output feedback controller based on the cascaded structure observer. The uniform exponential stability (USE) criterion ensures that the tracking error of the observer for the system state is bounded. The expected load pressure is constructed based on the expected trajectory to replace the actual load pressure, avoiding the influence of the nonlinear coupling between the load pressure and the input signal on the control system. Finally, a stable output feedback controller is obtained based on the backstepping control method and Hurwitz polynomial stability analysis. This study first applies the cascaded structure observer to the field of dual-spool electro-hydraulic valve control, providing a new theoretical framework and technical path for the high-precision control of the hydraulic system of construction machinery. Theoretical analysis shows that compared with the standard LESO, the cascaded structure observer can significantly reduce the online computational burden and effectively suppress the peak phenomenon, providing stronger estimation ability. Finally, a large number of simulation examples verify the effectiveness and superiority of the output feedback controller based on the cascaded structure observer. In all four test scenarios, the average tracking error of C1 (the output feedback controller designed based on the cascaded structure linear extended state observer) is about 5.1%, the average tracking error of C2 (the output feedback controller designed based on the standard structure linear extended state observer) is about 7.8%, and the average tracking error of C3 (the high-gain PID controller) is about 19.2%. The average control accuracy of the designed C1 controller is improved by 2.7% and 14.1% compared with C2 and C3, respectively. In terms of the estimation of external disturbances, the average error of C1 is 14% and the average error of C2 is 29.6%. The estimation accuracy of the former is improved by 15.6% compared with the latter. Full article

Aiming to solve the difficult problem of the miniaturization of servo valves, this paper designs a subminiature two-dimensional (2D) electro-hydraulic servo valve, which realizes the integration of the pilot stage and the power stage and significantly improves the work-to-weight ratio. Meanwhile, a high-power-density brushless DC motor (BLDC) is adopted as the electro-mechanical converter to further reduce the volume and mass. Firstly, the structure and working principle of the two-dimensional (2D) servo valve are described, and the mathematical model of the electro-mechanical converter is established. Aiming at the special working condition of the electro-mechanical converter with high-frequency oscillation at a small turning angle, this paper designs a position–current double closed-loop PID control algorithm based on the framework of the vector control algorithm (FOC). At the same time, the current feedforward compensation technique is included to cope with the high-frequency nonlinear disturbance problem of the electro-mechanical converter. The stability conditions of the electro-mechanical converter and the main valve were established based on the Routh–Hurwitz criterion, and the effects of the control algorithm of the electro-mechanical converter and the main parameters of the main valve on the stability of the system were analyzed. The dynamic and static characteristics of the 2D valve were simulated and analyzed by establishing a joint simulation model in Matlab/Simulink and AMESim. The prototype was fabricated, and the experimental bench was built; the size of the experimental prototype was 31.7 mm × 29.3 mm × 31 mm, and its mass was 73 g. Under a system pressure of 7 MPa, the flow rate of this valve was 5 L/min; the hysteresis loop of the spool-displacement input–output curve was 4.8%, and the linearity was 2.54%, which indicated that it had the ability of high-precision control and that it was suitable for the precision fluid system. The step response time was 7.5 ms, with no overshoot; the frequency response amplitude bandwidth was about 90 Hz (−3 dB); the phase bandwidth was about 95 Hz (−90°); and the dynamic characterization experiment showed that it had a fast response characteristic, which can satisfy the demand of high-frequency and high-dynamic working conditions. Full article

The swivel system of a hydraulic excavator is susceptible to pressure impact during start and stop, which significantly impacts the service life of the excavator. In this investigation into how varying speeds affect the dynamic characteristics of a swing motor’s buffer relief valve (BRV), the AMESim simulation model of the whole swing motor was established, and its validity was confirmed through experimental testing. The pressure overshoot rate and start–stop impact time of the BRV of a swing motor at 1000 rpm, 1500 rpm, and 2000 rpm, under different spring stiffnesses, were analyzed. Based on the mathematical model of the BRV, the influence of the main structural parameters of the BRV on its dynamic characteristics were analyzed using an AMESim simulation model of the whole swing motor. The results show that an increase in the rotational speed of the electric motor, while maintaining a constant spring stiffness, affects the pressure overshoot rates of both the buffer relief valve of the swing motor inlet (BRVSMI) and the buffer relief valve of the swing motor outlet (BRVSMO); specifically, when the set pressure is established at 20 MPa, the pressure overshoot rate is observed to be higher, and the start–stop impact time exceeds 25 MPa. During the start phase of the swing motor, the start impact time for the BRVSMI remains relatively constant at approximately 2.5 s, with the pressure overshoot rate stabilizing at around 0.8. Conversely, in the stop phase of swing motor, both the stop impact time and the pressure overshoot rate of the BRVSMO exhibit variability in their response to the structural parameters of the BRV. Under conditions of comparatively high pressure, it is recommended to increase the diameter of the spool damping hole, the mass of the valve core, and the viscous damping coefficient, while simultaneously reducing the guide rod diameter of the buffer plunger, as these modifications can effectively enhance the start–stop impact time and mitigate the pressure overshoot rate. Full article

A directional valve is a core component of the electro-hydraulic shakers in fatigue testing machines, controlling the cylinder or motor that drives the piston for reciprocating linear or rotary motion. In this article, a high-speed rotating directional valve with a symmetrical flow channel layout is designed to optimize the force on the valve core of the directional valve. A comparative analysis is conducted on the flow capacity of valve ports with different shapes. A steady-state hydrodynamic mathematical model is established for the valve core, the theoretical analysis results of which are verified through a Computational Fluid Dynamics (CFD) simulation of the fluid domain inside the directional valve. A prototype of the rotatory directional valve is designed and manufactured, and an experimental platform is built to measure the hydraulic force acting on the valve core to verify the performance of the valve. The displacement curves at different commutation frequencies are also obtained. The experimental results show that the symmetrical flow channel layout can significantly optimize the hydraulic force during the movement of the valve core. Under a pressure of 1 MPa, the hydraulic cylinder driven by the prototype can achieve a sinusoidal curve output with a maximum frequency of 60 Hz and an amplitude of 2.5 mm. The innovation of this design lies in the creation of a directional valve with a symmetric flow channel layout. The feasibility of the design is verified through modeling, simulation, and experimentation, and it significantly optimizes the hydraulic forces acting on the spool. It provides us with the possibility to further improve the switching frequency of hydraulic valves and has important value in engineering applications. Full article

As a key pressure control component of a hydraulic system, the noise of the direct-acting pressure reducing valve affects the working state of the system directly. However, the existing pressure reducing valves generally have the problem of excessive pure noise. In order to solve this problem, this study explored various structural combinations with the aim of improving the noise level of a direct-acting pressure reducing valve. Firstly, the flow field model of the direct-acting pressure reducing valve was established by using FEA (Finite Element Analysis), and the relationship between the flow field state and noise state was demonstrated through CFD (Computational Fluid Dynamics) simulation. Secondly, the position, number, and diameter of the oil holes on the valve spool were comprehensively analyzed, and the sound field analysis using LMS Virtual Lab was carried out. Finally, a prototype of the pressure reducing valve was manufactured, and the noise level before and after improvement was compared. The results showed that the effective sound pressure after improvement was reduced by 6.1% compared with that before at 50% of the opening, which verified the precision of the simulation model. The research results could provide a guideline for the design and improvement of direct-acting pressure reducing valves. Full article

Hydraulic spool valves may clamp under the action of sensitive particles when working in hydraulic oils that contain solid particles, which will then bring about a devastating detriment to the machines. According to the failure statistics of hydraulic systems organized by ISO, more than 80% of the operational failures of hydraulic systems are caused by fluid contamination, and particulate contamination is the most important factor causing spool valve stagnation. In this paper, we considered various factors, including the material, size, and concentration of particles and the spool postures, and built a systematic spool clamping mechanical model. A device was designed to measure the spool valve friction under the action of particles. The influence of particle material, concentration, and size on the friction force of spool valves was investigated. By experiments, we measured the spool clamping force under the action of each single factor and then fitted the datum quantity of spool clamping force and the empirical equation of pulsating quantity. The study results demonstrate three types of non-ideal postures of spools in a valve hole, which are off-center, tilting, and off-center with tilting. Those three postures can engender clamping risk zones with different ranges inside the clearance between spool valves, increasing the risk of spool clamping. The kind of particles is found to have a certain but limited impact on the spool clamping force. Usually, particles with a higher elastic modulus can trigger a larger spool clamping force, which is in line with the theoretical equation. Within a certain range, the probability density distribution of particle size tallies with the normal distribution function, where the “sensitive particles” take up 0.7–1 of the clearance between spool valves. A higher particle volume fraction in oils means a greater number of sensitive particles and a larger spool clamping force. For the particles of a similar size with the clearance between spool valves, when their volume concentration tops over the “sensitive concentration”, namely 5%, the risk of spool clamping rises in a drastic manner. This study provides a theoretical reference and an empirical equation for the mechanism of spool clamping under the action of particles, as well as a definite quantitative indicator for the prediction and estimation of spool clamping which is of positive significance for the study of the predictive maintenance of hydraulic equipment. Full article