Investigation of Semi-Active Hydro-Pneumatic Suspension for a Heavy Vehicle Based on Electro-Hydraulic Proportional Valve

Hydro-pneumatic suspension is widely used in heavy vehicles due to its nonlinear characteristics of stiffness and damping. However, the conventional passive hydro-pneumatic suspension can’t adjust parameters according to the complicated road environment of heavy vehicles to fulfill the requirements of the vehicle ride comfort. In this paper, a semi-active hydro-pneumatic suspension system based on the electro-hydraulic proportional valve control is proposed, and fuzzy control is used as the control strategy to adjust the?damping force of the semi-active hydro-pneumatic suspension. A 1/4?semi-active hydro-pneumatic suspension model is established, which is co-simulated with AMESim and MATLAB/Simulink. The co-simulation results show that the semi-active hydro-pneumatic suspension system can significantly reduce vibration of the vehicle body, and improve the suspension performance comparing with passive hydro-pneumatic suspension.

A New Kind of Pilot Controlled Proportional Direction Valve with Internal Flow Feedback

Proportional direction valve is one of the most fundamental elements in electronic-hydraulic control technique. Its function is to control the operating speed, direction, position, and strength of output force of the hydraulic actuator continuously. Considering the different application and the cost, the existing technique mainly includes the internal feedback valve used in open loop system, and the electronic closed loop controlled valve used in closed loop system. Because of their different mechanical structure and the gre at different in performance, it brings inconvenience for customer to select, also inconvenience for enterprise to produce. Aiming at this problem, the idea of combining the above two kinds of valves into one body is proposed first, and then the new valve＇s structure to realize this target is designed. The idea intends to apply the displacement pilot flow feedback control principle in present 2-position 2-way valve system to the proportional direction valve of 3-position 4-way system. Newly designed feed forward controller can decouple the interference between the internal feedback and the electronic closed loop. Redundant conversion is designed to electronic switch mode. Experiment on dynamic and static characteristic of new proportional direction valve in internal feedback control mode and electronic closed loop control mode is discussed to prove the new theory is correct. Although the new valve is of excellent dynamic response characteristic, its steady control characteristic in open loop control mode needs to be improved further. The research results prepare one new fundamental element for electronic-hydraulic control technology.

RESEARCH ON THE PERFORMANCE OF NEW TYPE OF PROPORTIONAL PESSURE AND FLOW CONTROL VALVE

A new closed loop flow controlling principle through correcting the valve'sopening area while load pressure is changing is carried out. Further more a principle using only oneproportional valve to compound control pressure and flow is suggested. By using very simpleproportional throttle valve in structure, the functions that five kinds of proportional valves orany two of them combined possess can be complimented. After analyzing, comparing, and testing thedynamic and static characteristics of valve with different controlling principles and main valvestructure styles, the optimized structure styles and control methods are achieved.

DYNAMIC CHARACTERISTICS OF LARGE FLOW RATING ELECTROHYDRAULIC PROPORTIONAL CARTRIDGE VALVE

A kind of cartridge servo proportional valve is discussed, which can be used for controlling large flow rate with high performance. By analyzing the structure principle of the valve, the transfer fimction of the valve is derived. With the transfer function, some structure elements that may affect its performance are investigated. Through the numerical simulation and test study, some principles of optimality and effective methods for improving the dynamic performance of the valve are proposed. The test results conform to the results of the theoretical analysis and simulation, which proves the correctness of the study and simulation works. The paper provides theoretical basis for engineering applications and series expanding design works

Flow Control for a Two-Stage Proportional Valve with Hydraulic Position Feedback

The current research mainly focuses on the flow control for the two-stage proportional valve with hydraulic position feedback which is named as Valvistor valve.Essentially,the Valvistor valve is a proportional throttle valve and the flow fluctuates with the change of load pressure.The flow fluctuation severely restricts the application of the Valvistor valve.In this paper,a novel flow control method the Valvistor valve is provided to suppress the flow fluctuation and develop a high performance proportional flow valve.The mathematical model of this valve is established and linearized.Fuzzy proportional-integral-derivative(PID)controller is adopted in the closed-loop flow control system.The feedback is obtained by the flow inference with back-propagation neural network(BPNN)based on the spool displacement in the pilot stage and the pressure differential across the main orifice.The results show that inference with BPNN can obtain the flow data fast and accurately.With the flow control method,the flow can keep at the set point when the pressure differential across the main orifice changes.The flow control method is effective and the Valvistor valve changes from proportional throttle valve to proportional flow valve.For the developed proportional flow valve,the settling time of the flow is very short when the load pressure changes abruptly.The performances of hysteresis,linearity and bandwidth are in a high range.The linear mathematical model can be verified and the assumptions in the system modeling is reasonable.

New Dead⁃zone Compensation Approach for Proportional Flow Valve

To solve the dead⁃zone in the output flow curve of the proportional flow valve without displacement sensor,a dead⁃zone compensation approach is proposed in this paper.Instead of detection and feedback of the valve spool position,the proposed approach adopted the pressure drop across the valve metering orifice to accomplish the dead⁃zone compensation.The first step was to test and get the_(max)imum output flow,Q_(max),at a preset reference pressure drop,such asΔP_(0).The next step was to construct the target compensation flow curve,which is a line through(0,0)and(ΔP_(0),Q_(max)).Then a compensation law was designed to approach the target curve.However,the research results show that the above strategy caused over⁃compensation once the actual pressure drop deviated fromΔP_(0).Thus a correction coefficient,β,was presented to correct the initial compensation law as the pressure drop deviated fromΔP_(0).For example,the test results indicate that the corrected compensation approach could reduce the dead⁃zone from 53.9%to 3.5%at a pressure drop of 1 MPa;as the pressure drop was increased to 5 MPa,the dead⁃zone was reduced from 51.7%to 3.5%.Therefore,the following conclusions can be drawn:the proposed compensation approach is feasible,which can effectively reduce the dead⁃zone and improve the output flow static performance of the proportional flow valve without spool displacement feedback.

Study on Valve Management of DEH for Steam Turbine

Valve management is one of the major functions of DEH for steam turbine. It has an important practical significance for the security and economy of the steam turbine. This paper starts from the valve configuration figure of the domestic-type 300 MW steam turbine, and then makes a simple comparison between the two types of valve governing modes. In order to realize the valve control, the structure of control system has been established, in which the roles of the mathematical functions are discussed. On the basis of the experiment of valve flow characteristic, this article carries out a quantitative study on the functions of the valve management and the parameter tuning method. Through a serious corrections, the sequence valve flow characteristic curve is obtained, which can provide significant guidance on the research of valve management of the similar steam turbines.

Methodology for expressing the flow coefficients of coupled throttling grooves in a proportional–directional valve

Calculating the flow coefficient of a spool-valve is complicated due to the coupling–throttling effect in the throttling grooves of a proportional–directional valve.In this paper,a methodology for expressing the flow coefficient of coupled throttling grooves is proposed to resolve that difficulty.With this purpose,an approach of a 3 D numerical simulation and an experimental bench were introduced based on the prototype of a commercial proportional valve.The results show consistency between the numerical simulation and the bench test.Based on that,the concept of‘saturation limit’is introduced to describe the value gap between the current and saturated flows,so that the flow-coefficient saturation limit of the prototype in the process can be deducted.Accordingly,an approximate flow coefficient suitable for coupled throttling grooves within finite variable space,which is based on three typical throttling structures(i.e.O-shape,U-shape,and C-shape)of the coupled throttling grooves,is obtained based on an orthogonal test.The model results are consistent with the numerical and experimental results,with maximum errors of less than 5.29%and 5.34%,respectively.This suggests that the proposed method is effective in approximating the flow coefficient.

Development of a novel two-stage proportional valve with a pilot digital flow distribution

Pilot two-stage proportional valves are widely used in high-power hydraulic systems. For the purpose of improving the dynamic performance, reliability, and digitization of the traditional proportional valve, a novel two-stage proportional valve with a pilot digital flow distribution is proposed from the viewpoint of the dual nozzle-flapper valve’s working principle. In particular, the dual nozzle-flapper is decoupled by two high-speed on/off valves (HSVs). First, the working principle and mathematical model of the proposed valve are determined. Then, the influences of the control parameters (duty cycle and switching frequency) and structural parameters (fixed orifice’s diameter and main valve’s spring) on the main valve’s motion are analyzed on the basis of theory, simulation, and experiment. In addition, in optimizing the value of the fixed orifice’s diameter, a new design criterion that considers the maximum pressure sensitivity, flow controllability, and flow linearization is proposed to improve the balance between the effective displacement and the displacement fluctuation of the main valve. The new scheme is verified by simulations and experiments. Experimental results of the closed-loop displacement tracking have demonstrated that the delay time of the main valve is always within 3.5 ms under different working conditions, and the tracking error can be significantly reduced using the higher switching frequency. The amplitude–frequency experiments indicate that a −3 dB-frequency of the proposed valve can reach 9.5 Hz in the case of ±50% full scale and 15 Hz in the case of 0%–50% full scale. The values can be further improved by increasing the flow rate of the pilot HSV.

COMPUTATIONAL FLOW RATE FEEDBACK AND CONTROL METHOD IN HYDRAULIC ELEVATORS

The computational flow rate feedback and control method, which can be used in proportional valve controlled hydraulic elevators, is discussed and analyzed. In a hydraulic elevator with this method, microprocessor receives pressure information from the pressure transducers and computes the flow rate through the proportional valve based on pressure-flow conversion real time algorithm. This hydraulic elevator is of lower cost and energy consumption than the conventional closed loop control hydraulic elevator whose flow rate is measured by a flow meter. Experiments arc carried out on a test rig which could simulate the load of hydraulic elevator. According to the experiment results, the means to modify the pressure-flow conversion algorithm are pointed out.

比例伺服阀非线性液动力模型修正与特性分析

比例伺服阀的高速运行以及油液流动状态直接影响液动力的变化,进而影响比例伺服阀和伺服机构的动静态性能。基于此,为明确比例伺服阀液动力的变化规律和特性,首先基于阀芯和阀体配合的节流口结构建立液动力的理论数学模型。然后结合流场仿真,分析不同开度和不同压差下液动力变化情况,明确液动力仿真结果和理论结果的偏差,修订液动力理论数学模型。最后,基于液动力测试平台,验证了不同开度和压差下液动力变化情况。结果表明:射流角的减小会导致稳态液动力不断增大,阀口开度的增大使稳态液动力呈现先增大后减小的趋势,同时在小开度下压差越大对应稳态液动力的峰值也越大,研究成果为比例伺服阀非线性补偿控制提供理论基础。

盾构螺机后仓门液压系统仿真控制研究

针对传统盾构螺旋输送机后仓门紧急关闭过程中液压系统流量大小不稳定及油缸和蓄能器关键参数设置不合理而易引起液压冲击,造成机械部件损伤等缺陷。提出一种带压力补偿的插装式比例流量阀控制系统流量大小。通过分析其结构组成及原理,建立了该阀AMEsim模型,并对模型仿真特性曲线进行了分析,得出其有较好的流量稳定性,控制精度高、动态响应性好,且利用仿真环境建立了螺机后仓门液压系统的AMEsim模型,分析了系统中蓄能器与液压缸的关键参数对后仓门紧急关闭的影响规律,结合该影响规律及比例流量阀的工作特性,为螺机后仓门液压系统的进一步升级改造提供理论依据。

高压阀口液动力补偿控制策略仿真分析

直动式比例伺服阀是一种新型的单级伺服阀,采用比例电磁铁或线性力马达直接驱动滑阀运动,具有成本低、频响高、抗污染能力强等优点,广泛应用于注塑机进给控制、轧机板厚控制系统等高速高精度液压控制系统中。传统的直动式比例伺服阀采用PID控制策略实现阀芯的精确位置控制,在高压大流量工况下(供油压力达到20 MPa、流量大于100 L/min),阀芯受到液动力扰动变得更加剧烈,易出现响应速度慢、阀芯抖动的现象,影响了比例伺服阀的控制精度。为了解决大液动力扰动的问题,提出了一种基于指数收敛干扰观测器的滑模控制器。通过建立阀芯动力学模型来设计滑模控制器,保证阀芯位置的高动态跟踪性能;使用基于指数收敛的干扰观测器,估计阀芯动力学模型中液动力的不确定性扰动,解决高压大流量工况下的阀芯液动力扰动补偿问题。搭建了比例伺服阀系统的联合仿真模型进行仿真验证,结果表明,提出的控制器可以解决高压大流量工况下阀芯液动力扰动对阀芯位置控制的干扰问题。

SP08-20先导式螺纹插装比例方向阀静态特性仿真与试验

SP08-20是一种用于方向控制的先导式螺纹插装比例方向阀,断电时,用作单向阀,通电时,用作节流阀,通过控制先导阀芯及主阀芯位置变化实现对阀的流量控制。此阀流道形状较为复杂,控制腔压力分布规律难以确定,且传统的液动力与流量经验公式本身准确性较差,导致在通过由经验公式构成的数学模型求解阀的静态特性时,模型计算结果与试验结果有较大的差异。故采用Fluent软件对SP08-20进行流场仿真得到其阀芯受力规律,利用曲线拟合的方式得到阀芯受力拟合式,据此求解静态数学模型,得到此阀的静态特性。试验结果表明,利用流场仿真的方式求解所得静态特性曲线与试验曲线具有较高的吻合度。

先导式电液比例溢流阀静态特性仿真与试验

先导式电液比例溢流阀是用来控制系统中油液压力的压力控制阀,可根据工况要求以电信号控制电磁力从而实现对液压系统的压力控制,由先导阀、主阀和手调安全阀组成。由于控制阀口通流状态较为复杂,采用流量经验公式和传统的液动力公式难以准确计算阀口通流量和阀芯所受液动力,数学模型计算结果与试验存在较大差异。为了较为准确地获得溢流阀的静态特性,采用Fluent软件分别对主阀和先导阀进行流场仿真计算,获得不同阀口开度和压差下的阀芯受力和阀口通流量。利用插值方式得到阀芯受力和阀口通流量的插值模型,据此求解静态数学模型,得到溢流阀静态特性曲线。结果表明,采用插值模型求解所得静态特性曲线与试验曲线的吻合度更高。

比例方向阀流致振动特性研究

随着液压技术向高速、高压和大功率方向发展,液压元件的振动噪声问题也日趋严重,噪声污染已成为制约液压技术发展的“瓶颈”。比例方向阀作为一种常用于工程机械等领域的控制元件,对其减振降噪方面的研究具有重要意义。分析了某型号比例方向阀的流致振动问题,针对比例阀的流场压力脉动特性、振动特性、减振降噪等方面展开了研究。对不同开度下的阀内流场进行数值模拟,分析比例方向阀压力脉动、湍流强度、空化程度等流动特征;设置监测点,得到流致振动的主频范围,并与预应力模态分析下的固有频率进行对比;对比例方向阀进行流固耦合数值模拟,探究影响振动能级的主要因素;总结比例方向阀振动机理,验证比例阀工作可靠性。

先导流量放大型比例方向流量阀特性仿真研究

由于缺少高动态的流量测量方法,导致直接测量先导级流量成为一大难点。为此,设计一种具有流量-位移转换功能的动态流量计,并将该流量计应用于位移-流量反馈型比例方向阀先导级,实现对先导阀流量的测量与控制,构成先导流量放大型比例方向流量阀。在SimulationX中搭建先导流量放大型比例方向流量阀仿真模型,研究其动、静态特性。结果表明:该阀具有良好的静态控制精度,能准确控制输出流量;主阀进出口压差越大,阀芯动态响应越快;负载变化会引起流量超调,但调节时间短。

位移-流量反馈式比例阀先导液阻匹配策略研究

高水基比例阀先导液阻桥路直接影响主阀的控制特性,多功能、多类型液阻构成的复杂先导液阻网络成为比例阀设计的关键。采用数学建模、流场仿真以及试验研究相结合的方式分析位移-流量反馈式高水基比例方向阀先导液阻桥路的液阻特性,考虑了主阀进液阀芯和阀套之间环形间隙的流量泄漏。结果表明:当环形间隙面积一定时,位移反馈槽宽度越大,位移反馈节流控制线性度越好,然而,位移反馈槽宽度越大,先导液桥流量需求越大,高速开关阀组匹配设计难度越大;回液液阻对液桥起背压作用,回液液阻尺寸越小,背压效果越好,位移反馈槽节流控制线性度越差。根据流场仿真结果,综合匹配设计高速开关阀组及进液液阻,通过试验验证了先导液阻网络各液阻尺寸匹配策略的正确性。

比例方向阀静态特性仿真与实验

比例方向阀是电液控制技术中最基础的元件之一,其作用是对液压执行机构的速度、方向、位置和输出力进行连续控制。在比例方向阀使用过程中,发现电压指令相同时,当比例方向阀阀口的压差较大时,随着压差的增加,流量出现了不增反减的现象。为了解释该现象,建立两种比例方向阀的静态仿真模型:第一种静态仿真模型基于液动力和阀口流量的经验公式;第二种静态仿真模型基于通过ANSYS Fluent流场数值计算得到的液动力和阀口流量插值公式。静态仿真结果表明:阀口流量不增反减的原因在于当压差增大时,液动力增加导致阀芯位移减小,进而使流量减小。实验结果证明:相比传统的经验公式,使用基于流场仿真数据得出的稳态液动力和阀口流量插值公式时,静态仿真结果更接近实验结果。

两通压力补偿器测试方法的研究

介绍一种ZDC两通压力补偿器的结构及工作原理,以及两通压力补偿器串联在比例换向阀进油口的流量输出稳定性原理。根据原理分析两通压力补偿器的常见故障,包括:主阀芯无动作、弹簧端面磨损或者断裂、梭阀阀芯卡阻。设计了一种两通压力补偿器的测试方法,能够测试流量与控制信号、压力与控制信号特性曲线。该方法能够快速、准确地诊断两通压力补偿器的常见故障部位,为设备疑难故障分析和两通压力补偿器的修复提供技术参考。