MEC-E5004 Fluid Power Systems - Laboratory Exercise 2 - Control of Electrohydraulic System - Background and Theory PDF

MEC-E5004
FLUID POWER SYSTEMS

Control of Electrohydraulic system
Background and theory
Methods to control an electrohydraulic valve
► Open loop control (no feedback)

► Compensation control
► Closed loop control (with feedback)
22.11.2016
Department of Mechanical Engineering / Engineering Design / Mechatronics / Fluid Power
2
An example of Open loop control
A microwave oven uses Open loop control;
it turns itself off after a pre-set time regard-
less of whether the food intended to be
heated is still frozen or has already dried out.
Disturbance
Disturbance
Fout(t)
p(t)
w(t) Open u(t) Valve F(t) y(t)
Process
Setting value loop control Control (actu ator) Process input Actual value
(command) (response)
(input value) (output value)
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3
An example of Compensation control
Throttle
Pressure
In Compensation control the disturbances, e.g.,

supply pressure and output flow are measured Inflow
and by using this data the Compensator strives to

keep the input and output flows equal thus Outflow
maintaining the fluid in the tank

exactly at the desired level. Measu re-
me nt
However, over a longer Measu re-
Fout,meas (t)
me nt
Disturbance
Disturbance
period of time the
Fout(t)
pmeas (t)
p(t)
measurement errors pile
u(t) F(t) y(t)
up and the desired level w(t)
Compen-
sator
Valve
(actu ator)
Process
Control Process input Actual value
cannot be kept. Setting value
(command)
(response)
(output value)
(input value)
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4
An example of Closed loop control
Setting
+ value
Controller
In Closed loop control the Actual output Pressure

-
value is constantly measured and fed back Control Measurement

valve
to a comparator that calculates the Inflow
difference between Setting value and

Actual value. Using this calculated value Outflow
(i.e., error) the controller controls the valve

(actuator).
Disturbance
Disturbance
Fout(t)
p(t)
In its simplest form w(t) + e(t) u(t) F(t) y(t)
Valve
the controller can be Setting value
(command) -
Error
Controller
Control (actuator) Process input
Process
Actual value
(response)
a logic realized with (input value) (output value)
wmeas(t) Measu re-

relays. Measured value me nt
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5
Controller
Relay logic
PID-controller
Advanced controllers
Ÿ Fuzzy
Ÿ Adaptive
Ÿ Model predictive w(t) + e(t) u(t) y(t)
Controller System
Ÿ Optimal Setting value
(command) -
Error Control Actual value
(response)
Ÿ Neural networks (input value) (output value)
Ÿ Etc.
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6
PID-controller
Setting
w(t) value
The input of PID-controller is the error e(t) u(t) y(t) + e(t)

(i.e., deviation between Setting value and Control
System
Actual value - Error
Actual value) and the output of the

controller is the control command u(t) to P
the system (process).
+
+ I
de
u = K P e + K I ò e dt + K D +
dt D
Control signal u is a sum of three different functions, whose mutual

domination is affected with tuning gain parameters KP, KI and KD.
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7
PID-controller w(t) Setting
value
u(t) y(t) + e(t)

PID-controller is often expressed Control
System
Actual value - Error
also in form
æ 1 de ö P
u = K P ç e + ò e dt + TD ÷÷
ç
è TI dt ø +
+ I
+
TI is integration time = KP / KI
TD is derivation time = KD / KP D
Again control signal u is a sum of three different functions, whose

mutual domination is affected with tuning gain parameter KP and
time constants TI and TD.
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PID-controller
Variations of PID-controller are
P-controller, PI-controller and PD-controller
All of these can be realized with PID-controller by suitable setting
values of gain parameters KP, KI, KD and/or time constants TI and TD.
Setting
w(t) Setting
value
w(t) value
u(t) y(t) + e(t) u(t) y(t) + e(t)

System System
Control Actual value - Error Control Actual value - Error
P P
+ +
+ I + I
+ +
D D
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9
Parameters of PID-controller
Setting
w(t) value
Proportional term (P) is always u(t) y(t) + e(t)

System
-
directly proportional to the error e(t). Control Actual value Error
Integral term (I) integrates the error e(t) and P
is thus constantly changing until error reaches +

+
value 0. This term eliminates the constant +
I
deviation between Setting and Actual value,

D
but may cause system oscillation.
Derivative term (D) monitors the rate of change of error e(t) and tries
to resist the change of the error value. This term stabilizes the system,
but it is sensitive to delays and high frequency noise.
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10
Effect of PID-controller parameters
Increasing the values of controller parameters (P, I, D) have the
following effect on the system characteristics, here presented with the
gains KP, KI, KD.
Parameter Rise time Overshoot Settling time Steady state error Stability
KP Shortens Increases Impact is low Decreases Diminishes
KI Shortens Increases Lengthens Removes Diminishes

Improves,
KD Impact is low Reduces Shortens No effect providing
KD is small
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Effect of PID-controller parameters
When the error e(t) 10
9
increases stepwise in uD(t)
8
an open loop control, uI(t)
7
the controller
Amplitude (L)
6
parameters (P, I, D)
5
produce following
4
responses.
3
2
1
0
0 1 2 3 4 5 6 7 8 9 10
t (s)
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12
Tuning PID-controllers
In 1942 J.G. Ziegler and N.B. Nichols developed two experimental
methods for tuning PID-controllers.
First method is often called Ultimate Cycling Method and it is used with
closed loop systems (i.e., feedback systems), and the another, often
called Process Reaction Curve Method is in turn used with open loop
systems (i.e., systems without feedback).
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13
Ziegler-Nichols tuning method
The first method (used in the Laboratory Exercise)
is implemented as follows:
First, all the gains (KP, KI, KD) of the

controller are set to zero, after which the gain
KP is increased until the system starts to
oscillate continuously.
This value of gain KP is so called critical gain
KP,crit and the time period of oscillation Tcrit
corresponding this gain can be ”read” from
response (time between two successive peaks).
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14
de
Ziegler-Nichols tuning method u = K P e + K I ò e dt + K D
dt
Using the experimentally defined values of KP,crit and Tcrit the gains
(KP, KI, KD) of the controller can be calculated as follows
Controller Kp KI KD
P 0.50ž KP,crit - -
PI 0.45ž KP,crit 1.2ž Kp / Tcrit -
PD 0.80ž KP,crit - Kp ž Tcrit / 8
PID 0.60ž KP,crit 2ž Kp / Tcrit Kp ž Tcrit / 8
Pessen rule 0.70ž KP,crit 2.5ž Kp / Tcrit 0.15 ž Kp ž Tcrit
Small overshoot 0.33ž KP,crit 2ž Kp / Tcrit Kp ž Tcrit / 3
No overshoot 0.20ž KP,crit 2ž Kp / Tcrit Kp ž Tcrit / 3
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æ 1 de ö
Ziegler-Nichols tuning method u = K P çç e + ò e dt + TD ÷÷
è TI dt ø
Correspondingly the gain KP and the time constants TI and TD of

the controller can be calculated as follows
Controller Kp TI TD
P 0.50ž KP,crit - -
PI 0.45ž KP,crit 0.83ž Tcrit -
PD 0.80ž KP,crit - 0.125ž Tcrit
PID 0.60ž KP,crit 0.50ž Tcrit 0.125ž Tcrit
Pessen rule 0.70ž KP,crit 0.40ž Tcrit 0.150ž Tcrit
Small overshoot 0.33ž KP,crit 0.50ž Tcrit 0.333ž Tcrit
No overshoot 0.20ž KP,crit 0.50ž Tcrit 0.333ž Tcrit
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Criteria regarding the quality of the control
Defined from the step response (see Figure in following pages)
Dead time td
The time that after a stepwise change in system’s setting value w is required for the process output y
to start changing.
Rise time tr
to first reach its new steady-state value at certain accuracy. E.g., 95 % rise time refers to the time that
passes before output y first reaches 95 % of its new steady-state value. Likewise 10–90 % rise time
refers to the time that passes when output y changes from 10 % of its new steady-state value to 90 %
of its new steady-state value. In addition to these, also 5–95 % rise time is used.
Time to first peak tp

to reach its first maximum value. This characteristic is also sometimes referred as Peak time.
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Defined from the step response (see Figure in following pages)
Overshoot
The ratio of difference between output y’s first maximum and its new steady-state value to its new
steady-state value (= a/b in following Figure). Sometimes this characteristic is marked with Mp,
maximum percentual overshoot.
Damping ratio
The ratio of difference between output y’s first maximum and its new steady-state value to the
difference between output y’s second maximum and its new steady-state value (= c/a in following
Figure).
Settling time ts
to reach and remain inside a band whose width is equal to ±5 % of the total change in y (sometimes
also other bandwidths are used, e.g., ±1 %, ±2 %).
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Defined from the step response (see Figure in following page)
Time period T
The time between output y’s two successive peaks (e.g., first and second maximum) or valleys.
Oscillation frequency f
The frequency that the system oscillated with (= 1/T).
Steady state error est

The constant deviation between system’s setting value w and actual output value y.
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Step response
1.6 In Figure’s case:
Time when setting value w is changed
Overshoot Time Second overshoot Dead time, ca. 1.0 s

1.4 period T
10–90 % Rise time, ca. 0.19 s
Time to first Steady state
a 5–95 % Rise time, ca. 0.23 s
1.2
peak tp error est
95 % Rise time, ca. 0.28 s
1
c Time to first peak, ca. 1.45 s
95 % First overshoot (a/b), ca. 53 %
0.8
Rise time tr Second overshoot, ca. 15 %
5 % Settling New steady-state value Damping ratio (c/a), ca. 0.28
0.6
time ts ±5 % Settling time, ca. 3.2 s
5–95 % b
Rise time tr Time period, ca. 1.0 s
0.4
0.2
10–90 %
Rise time tr
0
0 1 2 3 4 5 6
2nd order system and time delay 1 s
Time t (s) - Nominal frequency 1 Hz
Dead time td - Relative damping 0.2
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Test system in laboratory
Position servo
Velocity servo
System
Ÿ Hydraulic power unit
Ÿ Proportional valve
Ÿ Differential cylinder
Ÿ Load
Ÿ Transducers
- Pressures p1 and p2
- Position x and velocity x&
- Force F
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Real-time operating system – Simulink
Real-Time™
Simulink Real-Time™ is a software by MathWorks which enables
running Simulink® and Stateflow ® models in target (slave) computer
and realizing hardware-in-the-loop (HIL) simulations, rapid prototyping
of feedback control systems and other real-time applications. It
includes a driver library, real-time core and an interface between host
and target computers for real-time monitoring, parameter tuning and
data retrieving.
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Real-Time™
Fast measurement process in target machine
Ÿ Independent operating system → no interruptions, e.g., by Windows
Fast feedback control

Ÿ Measurement → difference in command and measured value
→ calculation of new control signal → new measurement → etc.
Fast HIL-simulation (Hardware-in-the-loop) or Software-in-the-loop

Ÿ The system is partly ”real hardware” and partly ”virtual hardware” (= simulation model)
User is involved in the control loop

Ÿ Interactivity
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23
Real-Time™
Software Possible control loop
application Parameter
developed in updating Control
Host computer
(measurement, Target
control, Host
(Simulink
simulation) is (Windows Process
downloaded to
Real-Time™
etc.)
Target kernel)
computer. Data Measurement
Development of Measurements, Process receives
software and contro and controls and the
control of process possible real-time process quantities
simulations can be measured
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Controlled quantity:
Simulated system Rotational
velocity of mass Feedback:
Rotational
Velocity servo velocity of mass
w
U
Actuator:
Hydraulic
motor
Control
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25
Load: Fluid and its inertia:
Characteristics of the - inertia
- static torque
- spring-mass-system
→ oscillation tendency
simulated system
w
U
Hydraulic motor:
- Leakage (pressure dependent) Piping between valve
- Friction torque (pressure dependent) and actuator:
- Friction torque (rotational velocity - elasticity of fluid
dependent)
- Friction torque (constant) Control
- Modelled using Wilson-model
PID-controller
Proportional directional control valve:
- Finite operational velocity
(reaction time ca. 10 ms, 0 → 100 %)
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Restrictions in the simulated system
Restricted quantities:
- Power (limiter: system’s electric motor)
- Pressure (limiter: system’s pressure controller in pump)
- Flow rate (limiter: pump’s displacement and rotational velocity)
If the change in system’s control parameter values does not result to a

change in the system’s response, it may be due to the these
restrictions.
Although not always considered in simulation models, in real systems
the power and its components are always somehow restricted.
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System’s Natural frequency – without control
Proportional directional control valve closed Testing the natural frequency
- Setting value → feedback
Stiffness (hydraulic spring constant) of the rotation system - Torque load as impulse
4Vk,2rad K
kH = K = bulk modulus of fluid Jt
2 p Vk, rad + 2Vpipe
Natural frequency of the rotation system

1 kH
fH =
2p Jt Vpipe Vk,rad Vpipe
Matlab computation code

f_hydr= sqrt(4*(V_rad)^2*K/(2*pi*V_rad+2*V_pipe_P)/I_pump)/(2*pi)
T_period= 1/(sqrt(4*(V_rad)^2*K/(2*pi*V_rad+2*V_pipe_P)/I_pump)/(2*pi))
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Tuning and Experimenting in Laboratory
Tune with Ziegler-Nichols method and make experiments
Ÿ Seek the value of gain KP (P-term) that results into the simulated system oscillating
with constant amplitude (= critical gain KP,crit)
► The stiffness and natural velocity of cylinder system are at lowest when the piston is
in the middle of its movement range!
Ÿ Write down the values of KP,crit and corresponding time period Tcrit
Ÿ Tune following controllers using these parameter values and Ziegler-Nichols tuning table
► P-controller
► PI-controller
► PID-controllers (Z-N parameter values + testing with different values of PID parameters E)
Ÿ Save the diagrams of simulated responses (Alt + Prt Scr) to a Word-file

Ÿ Evaluate the response characteristics (settling time, overshoot, remaining error, etc.)
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Research Assignment 2, Problem B.5
Table 1 presents empirical qualitative knowledge on how the increase
of the control parameter values affect on the quality of the control.
Compare tabulated information with the measurement and simulation
results gained with position and velocity servos. Comment, which
control and tuning methods produced good results and which poor
when the following properties are striven for
a) small steady state error
b) short rise time
c) short settling time
d) small overshoot
Present one sentence justification for both control cases separately. Also comment
whether the gained results were consistent with the information presented in Table 1.
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More to study and ponder
By changing the values of model parameters it is possible to study,
e.g., which kind of effect does the
Ÿ change of velocity range (high " low) have on the stability of the
velocity servo
Ÿ change of load (inertia or static torque) have on the system
Ÿ change of valve’s time constant have on the system
Ÿ transducer’s noise have on the system
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Experiments and their results
Characteristics Critical P PI PID PID PID PID
gain
KP,crit
Rise time 95 %
Overshoot
Damping ratio
Settling time 5 %
Time period
Steady-state error
Notes:
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Dynamics of the test system
Control Spool Piston Piston

command position velocity position
w + e u xv x
PID
Setting value Error
(command) -
(input value) Controller Valve dynamics System’s Integrator
dead time Cylinder
Measu re- Measu re-

me nt me nt
Velocity Position
control control
wmeas
Measured value
Actual value
(response)
(output value)
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w + e u xv x
PID
Setting value Error
(command) -
dead time Cylinder
Measu re- Measu re-

me nt me nt
Velocity Position
control control
wmeas
Measured value
Actual value
(response)
(output value)
qV,1 = flow rate of the cylinder’s plus chamber

Flow rates of the cylinder are qV,2 = flow rate of the cylinder’s minus chamber
p1 = pressure in the cylinder’s plus chamber
q V,1 = K q x V - K C p1 - C V ( p1 - p 2 ) p2 = pressure in the cylinder’s plus chamber
Kq = flow gain of the control valve
q V, 2 = K q xV - K C p 2 + C V ( p1 - p 2 ) KC = flow-pressure coefficient of the control valve
CV = leakage coefficient of the cylinder (depends on the piston seals)
xV = spool position of the control valve
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w + e u xv x
PID
Setting value Error
(command) -
dead time Cylinder
Measu re- Measu re-

me nt me nt
Velocity Position
control control
wmeas
Measured value
Actual value
(response)
(output value)
Cylinder pressures are
p& 1 =
Ke
(q V,1 - Ax& ) Ke = efficient bulk modulus of the system
V0 = volume of cylinder chambers
V0
x& = piston velocity
p& 2 = e (q V, 2 + Ax& )
K A = piston area under pressure
V0
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Equation of motion for cylinder piston where
m = movable mass
ma = m&x& = Fp,1 - Fp,2 - Fμ Fp,1 = pressure force affecting piston in cylinder’s plus chamber
Fp,2 = pressure force affecting piston in cylinder’s minus chamber
Fm = friction force of the cylinder (piston and piston rod seals)
Equation of motion can be written in form
m&x& = p1 A - p 2 A - bx& Þ m&x&& = p& 1 A - p& 2 A - b&x&

where
w + e u xv x
b = viscose damping Setting value
(command) -
Error
PID

dead time Cylinder
Measu re- Measu re -

me nt me nt
Velocity Position
control control
wmeas
Measured value
Actual value
(response)
(output value)
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Hydraulic natural frequency wH
w + e u xv x
PID
Setting value Error
(command) -
2K e A 2 dead time Cylinder
wH = Measu re-
me nt
Measu re -
me nt
mV0 Velocity
control
Position
control
wmeas
Relative damping z
Measured value
Actual value
(response)
(output value)
1 æ m (0 .5 K C + C V ) bV 0 ö
z = w H çç + ÷÷
2 è A2 2K e A2 ø
In addition to viscose friction b, the damping

of the system depends also on the flow-
pressure coefficient KC of the valve and the
leakage coefficient CV of the cylinder.
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37
LAST SLIDE
Laboratory Exercise 2: Control of Electrohydraulic system

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MEC-E5004

FLUID POWER SYSTEMS

► Open loop control (no feedback)

In Compensation control the disturbances, e.g.,

and by using this data the Compensator strives to

maintaining the fluid in the tank

However, over a longer Measu re-

In Closed loop control the Actual output Pressure

value is constantly measured and fed back Control Measurement

difference between Setting value and

(i.e., error) the controller controls the valve

a logic realized with (input value) (output value)

wmeas(t) Measu re-

The input of PID-controller is the error e(t) u(t) y(t) + e(t)

Actual value) and the output of the

Control signal u is a sum of three different functions, whose mutual

u(t) y(t) + e(t)

Again control signal u is a sum of three different functions, whose

u(t) y(t) + e(t) u(t) y(t) + e(t)

Proportional term (P) is always u(t) y(t) + e(t)

Integral term (I) integrates the error e(t) and P

is thus constantly changing until error reaches +

deviation between Setting and Actual value,

KP Shortens Increases Impact is low Decreases Diminishes

KI Shortens Increases Lengthens Removes Diminishes

First, all the gains (KP, KI, KD) of the

Correspondingly the gain KP and the time constants TI and TD of

Time to first peak tp

Steady state error est

Overshoot Time Second overshoot Dead time, ca. 1.0 s

Fast feedback control

Fast HIL-simulation (Hardware-in-the-loop) or Software-in-the-loop

User is involved in the control loop

If the change in system’s control parameter values does not result to a

Natural frequency of the rotation system

Matlab computation code

Ÿ Save the diagrams of simulated responses (Alt + Prt Scr) to a Word-file

Control Spool Piston Piston

Measu re- Measu re-

Measu re- Measu re-

qV,1 = flow rate of the cylinder’s plus chamber

Measu re- Measu re-

Cylinder pressures are

Equation of motion can be written in form

m&x& = p1 A - p 2 A - bx& Þ m&x&& = p& 1 A - p& 2 A - b&x&

(input value) Controller Valve dynamics System’s Integrator

Measu re- Measu re -

2K e A 2 dead time Cylinder

In addition to viscose friction b, the damping

Laboratory Exercise 2: Control of Electrohydraulic system

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