FACULTY OF ENGINEERING, ARTCHITECTURE & BUILT ENVIRONMENT

Lab Report 2
EK409, Mechatronic Lab VI, Fluid Power & Drives Lab
May - August 2020
Experiment 2:
Part 1 Closed-Loop Actuator with Variable-Displacement Pressure-
Compensated Pump
Part 2 Hydraulic Actuator with Counterbalance Valve

Name ID Course
1) Wong Wei Hao 1001746444 B.Eng (Hons)
2) Wong Wei Herng 1001746821 Mechatronic
3) Gabriel Wong Jung Yit 1001747052 Engineering
4) Choy Melvern 1001746771 (HYEK)
5) How Cheng Yang 1001746720
 TABLE OF CONTENTS

1. Introduction 3

2. Objectives 6

3. Safety Measures and Precautions 6

4. Apparatus and Material 6

5. Methodology 7

6. Results and Discussion 8

7. Conclusion 22

8. Reference 23

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Introduction

Part 1: Closed-Loop Actuator with Variable-Displacement Pressure-Compensated Pump

A closed-loop actuator with variable-displacement pressure-compensated pump is a special

hydraulic system created to be studied in this experiment. There are a few important components

in this system that worth noticing. First, an actuator is a component which convert and transform

the hydraulic energy generated by the pump with hydraulic fluids, into useful work, such as

moving loads, creating movements etc. A actuator is normally a motor, jack (the hydraulic jack

that lifts heavy loads) and sometimes, rotary components (a rotating shaft). Meanwhile, a closed-

loop hydraulic system is where the hydraulic fluids flow in the system is continuous between the

pump and the actuator without returning or flowing to the reservoir as contrast to an open-loop

system that flows back to a reservoir.

In this case, the variable-displacement pump controls the direction of the movement of

the actuator using its swash plate, while the pressure compensated control valve manipulates the

pressure, then the force of the system output. A spring is connected to the mechanism in the

variable-displacement pump, supporting the pumping action of the component. Under normal

circumstances, the displacement pump is not regulated by the pressure compensated control, thus

it pumps the fluid from the source and through the pump, then towards the actuator to create the

force. However, if a designated fluid pressure is to be achieved to generate a specific amount of

force at the actuator, the motion sensor (or the sensing line) connecting the actuator and the

pressure compensated valve will channel the fluid flow into the pressure compensated valve. At

the valve, a spring control can be manipulated by tightening or loosening the control to increase

or decrease the resistance of the valve, for example, 1000psi. This is to make sure the flow of

fluid does not push through the valve unless it has 1000psi as well, and as the moment the fluid

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flow is strong enough to push through the valve, meaning the fluid pressure is 1000psi, it will

flow back to the variable displacement pump through the fluid line connecting the pressure

compensated valve and the pump, and pushes a cylinder that has diameter than the spring at the

pump, generating larger force which forces the flow through the pump to reduce and maintain at

1000psi.

This system is suitable for the application where constant pressure is required throughout

the process and the output pressure and force can be manipulated from time to time based on the

weight of the loads and usages, such as heavy industry cooling system where the hydraulic fluids

are taken as coolant and constant flow pressure is required. The variable-displacement pump and

pressure-compensated control are popular in industrial usage due to their accessibility and easy

to be manipulated.

Part 2: Hydraulic Actuator with Counterbalance Valve

A counterbalance valve, also called as a brake valve, is especially used in places where loads are

suspended and moved around rapidly. It prevents the loads from dropping and allowing smooth

and quick unloading where the loads are being lowered steadily. It is oftentimes being used to

replace the pilot-operated check valve where they both enable the vertical unload to happen, but

the pilot-operated check valve has its restriction, where the unloading process will be segmented

into several suspending and dropping, offering slower and less safety unloading.

Similar to a pilot-operated check valve, a counterbalance valve has three main ports

connecting three different fluid lines: the returning fluid line, internal fluid line and the top pilot

line, and it is normally accompanied by a reverse flow check valve to aid its function. A

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counterbalance valve is also similar to a pressure-compensated valve with their triggering

condition, where they are normally a blocking valve unless a certain pressure has been applied

and the triggering pressure level is adjustable with a spring control that can be tightened or

loosened. When enough pressure is present at the internal pilot line, it will push open the plate

towards the top pilot line connection inside the valve, allowing flow through the valve. However,

if the spring control provides enough resistance, it will push the plate towards the line and stop

the fluid flow unless the fluid flow is stronger than the spring control again.

When the unloading starts by lowering the cylinder, the fluid starts to flow back from the

load actuator through the internal pilot line, the force is strong enough to push the plate toward

the top pilot line. However, this would cause the flow to be too strong and the descending of the

load would be too quick. Thus, the top pilot line is now functioning as a regulator for the valve

dynamically, channeling the flow from the fluid line and balances the pressure within the

counterbalance valve, making sure the plate in the valve maintains at the same location and

ensure a smooth descend.

In this experiment, both systems are being tested and studied by manipulating their

variables and observing the changes in the result generated. Discussion will be carried out to

identify the reasons causing the changes in data as compared to the default system.

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Objectives

By the end of this laboratory session, the students will be able to:

- Simulate the closed-loop actuator with variable-displacement pressure-compensated

control system and the hydraulic actuator with counterbalance valve system.

- Understand the working mechanism of the systems, and their applications in real-life

scenarios.

- Making changes to the systems and allowing the system to adapt to applications.

Safety Measures and Precautions

- Behave in the laboratory by following the regulations, do not eat in the laboratory, do not

run and always wear a suitable attire with lab coats etc.

- Make sure the computers used to conduct the laboratory works are fully functional and

installed with the applications required, such as MATLAB with sufficient features.

- Do not attempt to modify the source codes of MATLAB application.

- Avoid using the counterfeit copy of MATLAB software found on random internet source.

It is illegal and could be sentenced to punishment.

Apparatus and Materials

- MATLAB R2020a, the latest version of the MATLAB software available.

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Methodology

1. “Closed-Loop Actuator with Variable-Displacement Pressure-Compensated Pump” was

searched in Simulink examples.

2. The model of the system was applied in Simulink.

3. The initial pressure plots in cylinder and counterbalance valve were observed and

recorded.

4. Then, 4 distinctive variables were changed, and the pressure plots for cylinder and

counterbalance valve were observed and recorded again. The outcome was discussed.

5. Repeat Step 1 to Step 4 for the “Hydraulic Actuator with Counterbalance Valve”.

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Results and Discussion

Part 1: Closed-Loop Actuator with Variable-Displacement Pressure-Compensated Pump

The circuit diagram of closed-loop actuator with variable-displacement pressure-compensated

pump

Manipulated variables:

1. Relative amount of trapped air (From 0.001 to 0.1)

2. System temperature (60 degree Celsius to 10 degree Celsius)

3. Cylinder piston area A (From 0.005m2 to 0.5m2)

4. Cylinder piston area B (From 0.01m2 to 0.1m2)

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Default System Altered System

Cylinder pressure and Piston Position at Cylinder pressure and Piston Position at

Relative amount of trapped air = 0.001 Relative amount of trapped air = 0.1

Pump pressure and Valve Spool Position at Pump pressure and Valve Spool Position at

Relative amount of trapped air = 0.001 Relative amount of trapped air = 0.1

Discussion: The relative amount of trapped air within a system is detrimental towards the

system’s overall fluid pressure, as the more trapped air bubbles present in the system and

cylinders, the more pressure will be used to crush the air bubbles and wasted on it, and causes

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the decrease in pressure and lowering the efficiency and also the stability of the cylinders and

systems. This can be seen in the graph of cylinder pressure, where the cylinder pressure is

building up much slower when the relative amount of trapped air is 0.1, as the pressure built is

first used to overcome the trapped air pressure before actually creating useful forces on the

fluid flow and piston movements. The piston position plot shows that there are a few small

hiccups during the ascending of the piston, and this is caused by the trapped air bubbles as air

bubbles move a lot more randomly compared to hydraulic fluid upon pressure, and their effect

is more visible on the plot of valve spool position, where the stability of the system can be

seen affected by the excessive trapped air.

Cylinder pressure and Piston Position at Cylinder pressure and Piston Position at

System Temperature = 60 degree Celsius System Temperature = 10 degree Celsius

Pump pressure and Valve Spool Position at Pump pressure and Valve Spool Position at

System Temperature = 60 degree Celsius System Temperature = 10 degree Celsius

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Discussion: With the system temperature drastically lowered from 60 degree Celsius to 10

degree Celsius, the density and the viscosity of the hydraulic fluid is greatly increased, and

causing the overall pressure of the system to increase as well. This is because the higher

weight per unit volume would result in greater force exerted against the surface of the cylinder

piston as well as the system, and the high viscosity makes it harder to be pumped out of the

cylinder, thus both the cylinder and pump pressure are both generally higher in their plots

when the system temperature is 10 degree Celsius. Piston position is not affected as it

functions normally under 10 degree Celsius, but the valve spool position is slightly different

due to the higher viscosity in fluid, the fluidity of the fluid is lower, changing the flow pattern

of the fluid through the valve and causing the change in the valve spool position.

Cylinder pressure and Piston Position with Cylinder pressure and Piston Position with

Dead Volume A = 0.001m3 Dead Volume A = 0.1m3

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Pump pressure and Valve Spool Position with Pump pressure and Valve Spool Position with

Dead Volume A = 0.001m3 Dead Volume A = 0.1m3

Discussion: Dead volume is total clearance volume in a cylinder that cannot be closed on

when the piston is in the pumping motion. The larger the dead volume normally result in more

trapped air and lower efficiency because the pressure generated by piston is lost in the dead

volume in the cylinder before being transmitted into the fluid line. This is shown in the

cylinder pressure plot, where the overall pressure is much lowered and the slope of the graph

is much flatter as pressure takes longer time to be built up with high dead volume, more

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pumping cycle is needed to create the same pressure as before. The lowest peak pressure of the

pump pressure and valve spool position are also lower and the stability of the system is said to

be affected.

Cylinder pressure and Piston Position with Cylinder pressure and Piston Position with

Dead Volume B = 0.001m3 Dead Volume B = 0.1m3

Pump pressure and Valve Spool Position with Pump pressure and Valve Spool Position with

Dead Volume B = 0.001m3 Dead Volume B = 0.1m3

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 Discussion: Like the previous manipulated variable, but piston B is now chosen. Dead volume

is total clearance volume in a cylinder that cannot be closed on when the piston is in the

pumping motion. The larger the dead volume normally result in more trapped air and lower

efficiency because the pressure generated by piston is lost in the dead volume in the cylinder

before being transmitted into the fluid line. This is shown in the cylinder pressure plot, where

the overall pressure is much lowered and the slope of the graph is much flatter as pressure

takes longer time to be built up with high dead volume, more pumping cycle is needed to

create the same pressure as before. The lowest peak pressure of the pump pressure and valve

spool position are also lower, and the stability of the system is said to be affected.

Part 2: Hydraulic Actuator with Counterbalance Valve

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 The circuit diagram of hydraulic actuator with counterbalance valve.

Manipulated variables:

5. Relative amount of trapped air (From 0.005 to 0.5)

6. Hydraulic fluid (From ISO VG 22 to water-glycol 60/40)

7. Cylinder piston area A (From 0.005m2 to 0.5m2)

8. Cylinder piston area B (From 0.01m2 to 0.1m2)

Default system Altered System

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Cylinder pressure and Piston Position at Cylinder Pressure and Piston Position at

Relative amount of trapped air = 0.005 Relative amount of trapped air = 0.5

Counterbalance Valve Port Pressures and Counterbalance Valve Port Pressures and

Counterbalance Valve Flow Rates at Relative Counterbalance Valve Flow Rates at Relative

amount of trapped air = 0.005 amount of trapped air = 0.5

Discussion: As the relative amount of trapped air within the system increases, the efficiency of

the system decreases, because the fluid pressure supplied by the pump will first have to

overcome the air bubble pressure in the hydraulic fluid. The bubble will take some forces to

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burst and that will lower the overall fluid pressure inside the system. This explains why the

peak pressure in both sides of the cylinder when the amount of trapped air increased, and the

ascending/descending slope of the graphs is curvier. This is because the bubbles are taking

some of the pressure supplied by the pump, causes the rate of increase of the pressure in the

system to be lower. Lastly, when the fluid is released and pushed through the valve, again the

pressure is lost partially to the air bubbles, thus the flow rate increases/decreases much slower

compared to the flow rate in the default system.

Cylinder pressure and Piston Position with Cylinder pressure and Piston Position with

ISO VG 22 as hydraulic fluid water-glycol 60/40 as hydraulic fluid

Counterbalance Valve Port Pressure and Counterbalance Valve Port Pressure and

Counterbalance Valve Flow Rates with ISO Counterbalance Valve Flow Rates with water-

VG 22 as hydraulic fluid glycol 60/40 as hydraulic fluid

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Discussion: ISO VG 22 is a low density (841.24kg per m3) hydraulic fluid as compared to

water with density of 984.328kg per m3. Thus, with lower mass per unit area, the ISO VG 22

is easier to be pumped and lesser pumping force is required by the pump, unlike water that has

great mass per unit volume that exerts greater forces when being pump and causes slightly

higher peak pressure in cylinder pressure. Not only that, the piston position is observed to be

different between both systems, especially approaching the end of the process. This is because

water is less compressible compared to hydraulic fluid, it exerts stronger forces when the

piston pushes against the bottom of the cylinder and slightly lifting the piston up.

Cylinder pressure and Piston Position with Cylinder pressure and Piston Position with

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Cylinder piston area A of 0.005m2 Cylinder piston area A of 0.5m2

Counterbalance Valve Port Pressure and Counterbalance Valve Port Pressure and

Counterbalance Valve Flow Rates with Counterbalance Valve Flow Rates with

Cylinder piston area A of 0.005m2 Cylinder piston area A of 0.5m2

Discussion: With the piston area A greatly increase (0.005m2 to 0.5m2), the cylinder pressure

and counterbalance valve port pressure are greatly decreased. This is because the greater the

area of the surface, the smaller the pressure exerted according to Pascal's Principle (P= F/A,

pressure exerted on a medium is inversely proportional to the area of the contacting surface).

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Even when the other piston area (Area B) has not been changed, the drastic change in cylinder

area A has resulted in total imbalance in both cylinder and causing the loss of pressure almost

entirely. This further affects the piston position as the generated pressure was insufficient to

generate sufficient force to lift the piston in the supposedly ascending process, and instead the

piston were descending during the entire process. The counterbalance valve flow rate is also

affected by the low pressure generated, decreased drastically compared to the initial condition.

Cylinder pressure and Piston Position with Cylinder pressure and Piston Position with

Cylinder piston area B of 0.01m2 Cylinder piston area A of 0.1m2

Counterbalance Valve Port Pressure and Counterbalance Valve Port Pressure and

Counterbalance Valve Flow Rates with Counterbalance Valve Flow Rates with

Cylinder piston area B of 0.01m2 Cylinder piston area B of 0.1m2

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Discussion: The trend of changes of the results are generally identical with the variable above,

with the overall values in pressure and flow rate higher since the change of the area is not as

drastic as the previous set of variable. With the piston area B greatly increase (0.01m2 to

0.1m2), the cylinder pressure and counterbalance valve port pressure are greatly decreased.

This is because the greater the area of the surface, the smaller the pressure exerted according

to Pascal's Principle (P= F/A, pressure exerted on a medium is inversely proportional to the

area of the contacting surface). Even when the other piston area (Area A) has not been

changed, the drastic change in cylinder area A has resulted in total imbalance in both cylinder

and causing the loss of pressure drastically. This further affects the piston position as the

generated pressure was insufficient to generate sufficient force to lift and suspend the piston

steadily during the process, the low pressure can only lift the piston at a much slower rate and

did not managed to hold the piston at a point. The counterbalance valve flow rate is also

affected by the low pressure generated, decreased drastically compared to the initial condition.

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Conclusion

By the end of this experiment, the students have been able to simulate two advanced fluid power

and drives systems on MATLAB, namely the closed-loop actuator with variable-displacement

pressure-compensated pump system and hydraulic actuator with counterbalance valve. Both is

used in different engineering occasions where the first system is normally used in machines that

require stable and constant fluid flow and the latter is used where the load is required to be

lowered or suspended stably, as a replacement to pilot-operated check valve. The students are

now having more understanding on the mechanisms of the different valves and fluid circuit

connections, able to suggest the application of the system and making alteration to the system to

meet the engineering application required.

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Reference

1. Esposito, A. (2008). Fluid Power with Applications. (7th Edition). Pearson.

2. Durfee, W., Sun, Zongxuan., Van de Ven, J. (2015). Fluid Power System Dynamics.

(Revised Edition). Center for Compact and Efficient Fluid Power, University of

Minnesota.

3. Daines, JR. (2012). Fluid Power: Hydraulics and Pneumatics. (2nd Edition). Goodheart-

Willcox.

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