Proceedings of 2010 IEEE Student Conference on Research and Development (SCOReD 2010),
13 - 14 Dec 2010, Putrajaya, Malaysia
PID Controller Design for an Industrial Hydraulic
Actuator with Servo System
S Md Rozali1
1
Faculty of Electrical Engineering
Universiti Teknikal Malaysia Melaka
76109 Durian Tunggal,Melaka,Malaysia
sahazati@utem.edu.my
Abstract-Electro-hydraulic system (EHS) consists of several
dynamic parts which are widely used in motion control
application. These dynamic parts need to be controlled to
determine direction of the motion. Mathematical model of EHS is
required in order to design a controller for the system. In this
paper, system identification technique is used for system
modeling. Model of the system is estimated by using System
Identification Toolbox in Matlab. This process began with
collection of input and output data from experimental works. The
data collected is used for model estimation. Auto Regressive with
eXogeneous input (ARX) model is chosen as model structure of
the system. Based on the input and output data of the system,
best fit criterion and correlation analysis of the residual is
analyze to determine the adequate model for representing the
EHS system. By using Ziegler-Nichols tuning method, PID
controller is designed for the model chosen through simulation in
Simulink. In order to verify this controller, it is applied to the
real time system and the performance of the system is monitored.
The result obtained shows that the output of the system with
controller in simulation mode and experimental works is almost
similar. The output of the system also tracked the input given
successfully.
Keywords: Electro-hydraulic system, System identification,
ARX model, PID controller
I. INTRODUCTION
A. Electro-Hydraulic Actuator System
Electro-hydraulic actuator converts electrical signal
to hydraulic power [1]. It is used for delivering high actuation
forces and high power. It is widely used since it has simple
construction, low cost small size-to-power ratios and be able
to apply very large torques and forces with fast response time.
On the other hand, it is highly non-linear system with
uncertain dynamics which complicate the development of high
performance closed-loop controllers. Thus, the mathematical
representation of the system cannot sufficiently represent the
practical system [2]. Basically, single-rod and double-rod
actuator with either proportional valve or servo valve are used.
Since electro-hydraulic actuator can provide precise
movement, high power capability, fast response characteristics
and good positioning capability, its applications are important
in the field of robotics, suspension systems and industrial
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MF Rahmat2, N Abdul Wahab2, R Ghazali2, and
Zulfatman2
2
Faculty of Electrical Engineering
Universiti Teknologi Malaysia
UTM Skudai 81310,Johor,Malaysia
fuaad@fke.utm.my,aliza@fke.utm.my
process. Actuation time, hydraulic fluid supply pressure range,
acting type, over torque protection, local position indication
and integral pushbuttons and controls are among the important
specifications for electro-hydraulic valve actuators.
A suitable controller needs to be designed in order to
acquire the highest performance of the electro-hydraulic
actuator. The controller design requires the best mathematical
model of the system under control. Thus, a method of
identifying the system needs to be chosen so that the best
accuracy of the model can be obtained. Model identification of
electro-hydraulic position servo system based on hardware-in-
the-loop simulation environment of Real-time
Workshop(RTW) and system identification toolbox in Matlab
has been proposed [2],[3]. Nonlinear hybrid controller
composed of a proportional controller, a fuzzy controller and a
classical PID controller for the model attained has been
introduced. Similar work of modeling of electro-hydraulic
actuator also had been done [1]. In contrast, the proposed PID
controller designed for the model obtained is applied in
simulation mode only without applying it in real time mode.
Experimental work on recursive identification of an electro-
hydraulic system that represented by a discrete-time model in
open-loop and closed-loop configurations is presented [4]. The
unknown parameters of the system based on ARX model is
estimated by using Recursive Least Square (RLS) method
while model validation is verified by residual analysis. The
electro-hydraulic system is modeled as linear periodic systems
perturbed along periodic input and output trajectories [5]. By
define the valid range of the linear approximation, periodic
repetitive controller is designed and implemented within this
range. In contrary with the previous work where step and
sinusoidal signal is injected to the system, this research
applied Pseudo binary random sequence (PRBS) signals as
input to the electro-hydraulic actuator in order to model the
system. The root mean square (RMS) errors between the
outputs of actual plant and one-step predicted values
belonging to models with different orders have been compared
[6]. A development of model- based Fault Detection,
Identification and Estimation (FDIE) scheme has been done
for the condition monitoring of the EHA system [7]. It
combines the use of a model of EHA system with the
218
 multiple-model estimation algorithm to evaluate the reason with unbalanced loadings, uncertainties and disturbances [19].
and severity of a fault present. Based on radial basis function Block control, sliding mode control and integral control
(RBF) neural network, a research has been done to develop a techniques has been combined to design a controller in order
model reference adaptive PID control to improve the control to force an EHA system driven by servo valve to track a given
performance of hydraulic parallel robot [8]. RBF neural chaotic trajectory [20]. Thus, it is able to compensate the
network is also used to identify the hydraulic servo system on- inherent nonlinearities of the actuator and to reject external
line and then regulate the PID parameters on-line which makes constant disturbances.
the system more adaptive. In order to control the velocity of
B. Modeling of Electro-Hydraulic Actuator System
hydraulic actuator, robust design techniques are suggested [9].
The effectiveness of the controllers for the system is illustrated A mathematical model of electro-hydraulic actuator
through simulations for several values of the model’s consists of the dynamics of the system disturbed by an
uncertain parameters. external load and the dynamics of a servo valve. The linear
Large variation of the effective bulk modulus of the differential equations that describe the actuator-valve
working fluid which is due to the absence of a heat exchanger dynamics are given by [9]
v p (t ) = [AP (t ) − bv (t ) − F (t )]
is overcome by adaptive control scheme [10]. The error
• 1 (1)
L p L
equations for velocity, acceleration and jerk which are m
4β
[ ]
•
generated in the design procedure of the standard back- P L (t ) = K f x v (t ) − K tp PL (t ) − Av p (t ) (2)
stepping control scheme are used in this new scheme. V
Dynamic model of the entire actuator incorporating highly Where
non-linear hydraulic functions and the LuGre dynamic friction v p = piston velocity
model is used to arrive at a suitable controller [11]. By PL = hydraulic pressure
applying an adaptive observer in the controller the use of FL = external load disturbance
acceleration measurement is avoided. On the other hand, state x v = spool valve displacement
estimation of electro-hydraulic actuator by using proportional
A = piston surface area
integral observer is presented [12]. The proposed approach
utilizes the complete model of the system including the m = mass of theload
nonlinear dynamics and the performance is demonstrated with β = effective bulk mod ulus
the simulated results. b = viscous damping coefficient
Repetitive control which is new control scheme is V = total volume of hydraulic oil in
proposed where the controlled variables follow periodic the piston chamber and the connecting lines
reference commands [13]. Derivation of sufficient conditions
for the stability of repetitive control systems and modified
For zero initial conditions, the Laplace Transform of the
repetitive control systems is done by applying the small gain
equations (1) – (2) produced the following input-output
theorem and the stability theorem for time-lag systems.
relation:
Combination of various robust control techniques such as
integral-block, sliding mode and H-infinity control is U p ( s ) = H ( s ) X v ( s ) + H L ( s ) FL ( s ) (3)
implemented to design controller forcing electro-hydraulic
system to track a chaotic reference trajectory [14]. This Where
approach enables one to compensate the inherent 4 β AK f (4)
H (s) =
nonlinearities of the actuator and reject matched external ( ms + b)(Vs + 4 β K tp ) = 4bA 2
disturbances and attenuate mismatched external disturbances. − 4βK tp − sV (5)
H L ( s) =
A discontinuous controller which is able to track (ms + b)(Vs + 4 βK tp ) + 4bA2
force reference trajectory system is designed by applying
sliding mode control technique [15]. Instead of fixed boundary The transfer function of solenoid can be approximated by the
layers, sliding mode controller with varying boundary layers
has been proposed to improve the tracking performance of a servo valve spool position gain denoted by k v . Thus, input-
nonlinear EHA position servo system [16]. By using a method output relation (3) can be rewritten as
called nonlinear Quantitative feedback Theory (QFT), a robust U p ( s ) = H ( s) k vVin ( s ) + H L ( s ) FL ( s ) (6)
time-invariant controller is designed for EHS [17]. In order to
form a discontinuous controller for hydraulic valve, a new Where
control strategy which combines the classical fuzzy control Vin ( s ) = laplace transform of the control
theory and tri-state valve technology is presented [18]. An
voltage vin (t )
integrated hybrid design, consisting of two independent sets of
cylinder controllers (a feed-forward controller and a fuzzy
tracking controller) and one coordinate fuzzy controller is also Using equations (1)-(2), linear system with uncertain structure
proposed for a dual-cylinder electro-hydraulic lifting system is derived in state space form as
which is used to achieve a synchronized positioning objective d (7)
x (t ) = A ( q ) x (t ) _ B ( q )v (t ) + D F (t )
0 0 in 0 L
dt

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 y(t ) = C0 x(t )
Where
⎡v p (t ) ⎤
x(t ) = ⎢ ⎥
⎣ PL (t )⎦
⎡− b / m A/ m ⎤ sensor to track the location of the load. Multi sine signal with
A0 (q) = ⎢ ⎥ three different frequencies that is represented by equation (9)
⎣− 4q1 A / V − 4q1q2 / V ⎦
⎡0 ⎤ [21]. This signal is preferable compared to original sinusoidal
B0 (q) = ⎢ ⎥
⎣4q1q3 k v / V ⎦
⎡− 1 / m⎤
D0 = ⎢ ⎥ multi sin e = cos( 0.5t s ) + cos( 2t s ) + cos(5t s ) (9)
⎣0 ⎦
C0 = [1 0]
The objectives of this paper are to represent a mathematical
model of electro-hydraulic actuator (EHA) system using
system identification technique. It is followed by designing
suitable PID controller for the system in simulation and real-
time mode.
II. EXPERIMENTAL AND SIMULATION SETUP
The electro-hydraulic system that is used in this study
is composed of a single-rod hydraulic cylinder driven by a
direct servo valve Bosch Rexroth 4WREE6, 40 lpm flow rate
at 70 bars. The dimension of hydraulic cylinder is
63mm/30mm/300mm. Piston position is measured by using
300mm draw wire sensor while 100bar pressure transducers
are attached to measure the pressure into and from the
cylinder. NI PCI 6221 card is used as interface between
Matlab programs in PC with electro-hydraulic test bed.
Mathematical modeling is a description of a system
in terms of equations. It can be divided into two parts;
physical modeling and system identification. In this research,
system identification technique is applied to attain the model
of the system. Multi sine input is injected to the EHS through
Simulink to capture the position of the load which is recorded
by draw wire sensor. The collected input and output data is
stored in workspace Matlab. This data is used for model
estimation and validation part. Validation process is done in
order to compare the estimated model output with the real
output from the experiments [22]. By looking at the best fit
criterion parameter, the validated model will be accepted [1].
Open-loop testing is done in simulation mode by inject step
and sine input to the model obtained so that a suitable
controller can be designed to improve the performance of the
system.
Based on Ziegler-Nichols tuning method PID
controller is designed by inserted the calculated parameters in
PID block in Simulink and examined the output result. In
simulation mode, the PID controller is connected to the
discrete transfer function model in Simulink block only. The
output response is observed and recorded. It is followed by
inserted the similar PID in a real-time system where it is
located in the forward path of real-system. The different
between this mode and the previous mode is the latter used the
electro-hydraulic actuator system itself instead of discrete
transfer function model in the previous one. The output
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(8) response is also recorded and compared with the output
response attained from the simulation mode.
A. Model estimation
Electro-hydraulic actuator system that is used in this work
is an open-loop system with draw wire sensor acts as position
and illustrated in Figure 1 is chosen as the input to the system
signal in order to capture the dynamic characteristic of the
system.
3
2
1
0
-1
-2
-3
0 200 400 600 800 1000 1200 1400 1600
Figure 1. Multi sine signal with three different frequencies
This signal is injected to the electro-hydraulic system and the
output of the system is recorded. Several sets of 1500 numbers
of input and ouput data with sampling time 50ms are collected
for model estimation and validation.
B. Design of Controller
PID (proportional integral derivative) control is one of the
earlier control strategies. Since it has simple control structure
which was understood by plant operators and which they
found relatively easy to tune, it still have wide range of
applications in industrial control. By tuning the value of Kp, Ki
and Kd of the PID controller, the performance of the system
such as rise time, overshoot, settling time and steady state
error can be improved. Though the output of the system with
this controller will never reach zero steady state error, Kp or
proportional controller is used to assure the output reach the
reference input. Ki or integral controller is given to the system
in order to obtain zero or very small steady state error.
Derivative controller or Kd will improve the speed
performance of the system. Sometimes derivative action may
not be required since the proportional and integral action
already produce good output response [23]. The tuning value
of Kp, Ki and Kd are determined by using Ziegler-Nichols
tuning method [23],[24]. The critical gain, Kcr and critical
period of oscillation, Tcr need to be determine before the
tuning process. The value of Kp, Ki and Kd is adjusted from
this two parameters based on Ziegler-Nichols tuning rules.
220
 III. RESULTS
A. Model Estimation TABLE I. THE CALCULATED VALUE OF KP, KI AND KD FOR PID
CONTROLLER

Figure 2 shows the relationship between the input, u1 and the Input Kp Ki Kd
output, y1 of the electro-hydraulic system when multi sine Step 0.276 0.028 0.09
input is injected to it. Sine 1.8 0.03 0.01
Input and output signals
50

Figure 3 shows the block diagram of ARX model

without controller with step input. The same model also
y1

-50
injected with sine input.
0 500 1000 1500 2000 2500

input
10

5
To Workspace
u1

-5
0.01944 z3 +0.6005 z 2 -1.014 z+0.5188
-10
0 500 1000 1500 2000 2500 z 4 -2.056 z 3 +1.186 z2 +0.1772 z-0.3061 Scope
Time
Step
Discrete
Figure 2. The input-output data of EHA system Transfer Fcn
output

To Workspace 1
These input and output data is divided into two parts.
The first part is used to estimate the model of the system while Figure 3. The model with step input
the other part for model validation. Auto-regressive
Exogenous (ARX) model is selected as the model structure of The output response with each step and sine input is illustrated
the system since it is the simplest model incorporating the in Figures 4 and 5 correspondingly.
stimulus signal. The estimation of ARX model is the most
efficient of the polynomial estimation methods because it is 120

the result of solving linear regression equations in analytic 100

form. The solution also satisfies the global minimum of the 80

loss function.
The model estimated can be accepted when the best
60

fit percentage is more than 90% [22]. Besides, from the 40

residuals analysis, the auto correlation and cross correlation of 20

input and output data should be in the range of confidence 0

interval. Validation of the data shows that 92.8% best fit 0 10 20 30 40 50 60 70 80 90 100

meaning that the estimated model is almost tracking the real

output data from the experiments. All these process is done Figure 4. Response of the model with step input
through System Identification Toolbox in Matlab.
The polynomial model obtained is in the form of 15

discrete time equation which is represented as follow 10

A(q) = 1 − 2.056q −1 + 1.186q −2 + 0.177q −3 − 0.3061q −4

5

B(q) = 0.01944q −1 + 0.6005q −2 − 1.014q −3 + 0.5188q −4 (10)

0

The transfer function for ARX model is given by [21] -5

B(q)
G (q) =
A(q) -10
0 10 20 30 40 50 60 70 80 90 100

Thus, the transfer function for the system can be represented

Figure 5. Response of the model with sine input
by
−1 −2 −3 −4
0.01944 q + 0.6005 q − 1.014 q + 0.5188 q Referring to Figure 4, the system produced large steady-state
G (q) =
1 − 2.056 q −1 + 1.186 q − 2 + 0.177 q −3 − 0.3061q − 4 (11) error when step input is injected to it. Figure 5 also illustrates
that the sine input caused the output of the system being
unstable and oscillate. Although the model is accepted as the
B. PID Controller best model for the system, the stability of the model need to be
The critical gain for the model attained is Kc = 0.46 with improved.
critical period, Tc = 7.1481. From calculation based on
Ziegler-Nichols tuning method and manual adjustment, the The block diagram of the system with PID controller
parameters of PID controller with different input are shown in injected with step input in simulation mode is shown in
Table I. Figures 6. The same procedure is repeated with sine input. The

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 output responses with both inputs are shown in Figures 7 and Based on this figure the response of the system with step and
8. sine input are revealed by Figures 10 and 11 respectively.
0.06

input
0.05
To Workspace 1
0.04
0.01944 z 3 +0.6005 z2 -1.014 z+0.5188
PID
z4 -2.056 z 3 +1.186 z 2 +0.1772 z-0.3061 Scope 0.03
Step
Discrete Discrete
PID Controller Transfer Fcn output 0.02

To Workspace 2
0.01

Figure 6. System with PID controller with step input 0

-0.01
0.06 0 100 200 300 400 500 600

0.05
Figure 10. Response of real-time PID controller with step input (experiment)
0.04

0.03

0.03
0.02

0.02
0.01

0.01
0

0
0 5 10 15 20 25 30 35 40 45 50 -0.01

-0.02
Figure 7. Response of the system with PID controller with step input
(simulation) -0.03
0 100 200 300 400 500 600

0.04 Figure 11. Response of real-time PID controller with sine input (experiment)
0.03

Figures 10 and 11 show that the outputs from real-time

0.02
experiments are almost similar with the output attained from
0.01
simulation which produce very small steady-state error and
0
fast response time. It also can be seen that the output tracked
-0.01 the input with very small error. The setting value of Kp, Ki and
-0.02
Kd of the PID controller is acceptable and improve the
-0.03
performance of EHA system. This is proved by the increment
0 5 10 15 20 25 30 35 40 45 50
of the best fir of the model from 92% to 98%. A slight
Figure 8. Response of the system with PID controller with sine input different between input and output happened because the
(simulation) electro-hydraulic system which is nonlinear model is modeled
in linear model and some nonlinearity and uncertainties
Based on Figures 7 and 8, the output response of the system characteristic are ignored.
with step and sine input is improved by adding PID controller
in the forward path of system. The system produced very IV. CONCLUSION
small steady-state error with both inputs. The output of the System identification technique has been successfully
system also tracked the input given to it. On the other hand, applied to electro-hydraulic system in order to produce the
Figure 9 shows the similar PID is inserted in the forward path best linear discrete model of the system. PID controller is
of the system in real-time mode. designed effectively for the system and applied in both
simulation and real-time mode. The value of Kp, Ki and Kd is
Displacement
Tracking Voltage Input determined by Ziegler-Nichols tuning method since this tuning
Reference to the Valve Position
method is used widely. Step and sine input are injected to the
To Workspace
system and the simulation result shows that the output tracked
Sine Wave
PID Input Disp
the input. The real-time experiments also proved the result
Saturation
where the output obtained is almost similar with the output
Discrete
PID Controller Hydraulic System Sensor Output
Displacement (m)
response from simulation mode.
Step LVDT

Tracking Signal
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