Numerical Simulation and Experimental Study of Heat-fluid-solid Coupling of Double Flapper-nozzle Servo Valve

The double flapper-nozzle servo valve is widely used to launch and guide the equipment. Due to the large instantaneous flow rate of servo valve working under specific operating conditions, the temperature of servo valve would reach 120℃ and the valve core and valve sleeve deform in a short amount of time. So the control precision of servo valve significantly decreases and the clamping stagnation phenomenon of valve core appears. In order to solve the problem of degraded control accuracy and clamping stagnation of servo valve under large temperature difference circumstance, the numerical simulation of heat-fluid-solid coupling by using finite element method is done. The simulation result shows that zero position leakage of servo valve is basically impacted by oil temperature and change of fit clearance. The clamping stagnation is caused by warpage-deformation and fit clearance reduction of the valve core and valve sleeve. The distribution roles of the temperature and thermal-deformation of shell, valve core and valve sleeve and the pressure, velocity and temperature field of flow channel are also analyzed. Zero position leakage and electromagnet＇s current when valve core moves in full-stroke are tested using Electro-hydraulic Servo-valve Characteristic Test-bed of an aerospace sciences and technology corporation. The experimental results show that the change law of experimental current at different oil temperatures is roughly identical to simulation current. The current curve of the electromagnet is smooth when oil temperature is below 80℃, but the amplitude of current significantly increases and the hairy appears when oil temperature is above 80℃. The current becomes smooth again after the warped valve core and valve sleeve are reground. It indicates that clamping stagnation is caused by warpage-deformation and fit clearance reduction of valve core and valve sleeve. This paper simulates and tests the heat-fluid-solid coupling of double flapper-nozzle servo valve, and the obtained results provide the reference value for the design of double flapper-nozzle force feedback servo valve.

Analysis of the Internal Characteristics of a De ector Jet Servo Valve

In current research on deflector jet servo valves, the receiver pressure estimated using traditional two-dimensional simulation and theoretical calculation is always lower than the experimental data; therefore, credible information about the flow field in the prestage part of the valve can hardly be obtained. To investigate this issue and understand the internal characteristics of the deflector jet valve, a realistic numerical model is constructed and a three-dimensional simulation carried out that displays a complex flow pattern in the deflector jet structure. Then six phases of the flow pattern are presented, and the defects of the two-dimensional simulation are revealed. Based on the simulation results, it is found that the jet in the deflector has a longer core area and the fluid near the shunt wedge cannot resist the impact of the high-speed fluid. Therefore, two assumptions about the flow distribution are presented by which to construct a more complete theoretical model. The receiver pressure and prestage pressure gain are significantly enhanced in the calculations. Finally, special experiments on the prestage of the servo valve are performed, and the pressure performance of the numerical simulation and the theoretical calculation agree well with the experimental data. Finally, the internal mechanism described by the theoretical and numerical models is verified. From this research,more accurate numerical and theoretical models are proposed by which to figure out the internal characteristics of the deflector jet valve.

Influence of Magnetic Reluctances of Magnetic Elements on Servo Valve Torque Motors

The current research of electro-hydraulic servo valves mainly focuses on the vibration, pressure oscillating and source of noise. Unfortunately, literatures relating to the study of the influence of the magnetic reluctances of the magnetic elements are rarely available. This paper aims to analyze the influence of the magnetic reluctances of the magnetic elements on torque motor. Considering these magnetic reluctances ignored in previous literatures, a new mathematical model of servo valve torque motor is developed and proposed based on the fundamental laws of electromagnetism. By using this new mathematical model and the previous models, electromagnetic torque constant and magnetic spring stiffness are evaluated for a given set of torque motor parameters. A computer simulation by using AMESim software is also performed for the same set of torque motor parameters to verify the proposed model. The theoretical results of electromagnetic torque constant and magnetic spring stiffness evaluated by the proposed model render closer agreement with the simulation results than those evaluated by the previous models. In addition, an experimental measurement of the magnetic flux densities in the air-gaps is carried out by using SFL218 servo valve torque motor. Compared with the theoretical results of the magnetic flux densities in the air-gaps evaluated by the previous models, the theoretical results evaluated by the proposed model also show better agreement with the experimental data. The proposed model shows the influence of the magnetic reluctances of the magnetic elements on the servo valve torque motor, and offers modified and analytical expressions to electromagnetic torque constant and magnetic spring stiffness. These modified and analytical expressions could provide guidance more accurately for a linear control design approach and sensitivity analysis on electro-hydraulic servo valves than the previous expressions.

Research on the jet characteristics of the deflector–jet mechanism of the servo valve

In view of the complicated structure of the deflector-jet mechanism,a mathematical model based on the turbulent jet flow theory in the deflector-jet amplifier is proposed.Considering the energy transformation and momentum variation,an equation of the flow velocity distribution at the key fluid region is established to describe the morphological changes of the fluid when it passes through the deflector and jets into the receiver.Moreover,the process is segmented into four stages.According to the research results,the oil enters the deflector and impinges with the side wall.Then one part of the oil＇s flow velocity decreases and a high pressure zone is formed by the oil accumulation,the other part of the oil reverses out of the deflector along the side wall.Prior to entering the receiver,the flow is a kind of plane impinging jet.Virtually,the working pressure of the receiver is generated by the impact force,while the high speed fluid flows out of the receiver and forms a violent vortex,which generates negative pressure and causes the oil to be gasified.Compared with the numerical simulation results,the turbulent jet model that can effectively describe the characteristics of the deflector-jet mechanism is accurate.In addition,the calculation results of the prestage pressure characteristic have been verified by experiments.

Characteristics Prediction Method of Electro-hydraulic Servo Valve Based on Rough Set and Adaptive Neuro-fuzzy Inference System

Synthesis characteristics of the electro-hydraulic servo valve are key factors to determine eligibility of the hydraulic production. Testing all synthesis characteristics of the electro-hydraulic servo valve after assembling leads to high repair rate and reject rate, so accurate prediction for the synthesis characteristics in the industrial production is particular important in decreasing the repair rate and the reject rate of the product. However, the research in forecasting synthesis characteristics of the electro-hydraulic servo valve is rare. In this work, a hybrid prediction method was proposed based on rough set（RS） and adaptive neuro-fuzzy inference system（ANFIS） in order to predict synthesis characteristics of electro-hydraulic servo valve. Since the geometric factors affecting the synthesis characteristics of the electro-hydraulic servo valve are from workers＇ experience, the inputs of the prediction method are uncertain. RS-based attributes reduction was used as the preprocessor, and then the exact geometric factors affecting the synthesis characteristics of the electro-hydraulic servo valve were obtained. On the basis of the exact geometric factors, ANFIS was used to build the final prediction model. A typical electro-hydraulic servo valve production was used to demonstrate the proposed prediction method. The prediction results showed that the proposed prediction method was more applicable than the artificial neural networks（ANN） in predicting the synthesis characteristics of electro-hydraulic servo valve, and the proposed prediction method was a powerful tool to predict synthesis characteristics of the electro-hydraulic servo valve. Moreover, with the use of the advantages of RS and ANFIS, the highly effective forecasting framework in this study can also be applied to other problems involving synthesis characteristics forecasting.

2D SIMPLIFIED SERVO VALVE

A novel pilot stage valve called simplified 2D valve, which utilizes bothrotary and linear motions of a single spool, is presented. The rotary motion of the spoolincorporating hydraulic resistance bridge, formed by a damper groove and a crescent overlap opening,is utilized as pilot to actuate linear motion of the spool. A criterion for stability is derivedfrom the linear analysis of the valve. Special experiments are designed to acquire the mechanicalstiffness, the pilot leakage and the step response. It is shown that the sectional size of thespiral groove affects the dynamic response and the stiffness contradictorily and is also verysensitive to the pilot leakage. Therefore, it is necessary to establish a balance between the staticand dynamic characteristics in deciding the structural parameters. Nevertheless, it is possible tosustain the dynamic response at a fairly high level, while keeping the leakage of the pilot stage atan acceptable level.

GIANT MAGNETOSTRICTIVE ACTUATOR IN SERVO VALVE AND MICRO PIPE ROBOT

Performance of giant magnetostrictive material (GMM) is introduced. Principleof work, basic structure and key techniques of giant magnetostrictive actuator (GMA) are analyzed.Its dynamic models of magneto-mechanical coupling are established. The structure and principle ofthe pneumatic servo valve and the micro pipe robot with new homemade GMM are presented. Theexperiment is carried out under typical working conditions. The experiment results show that the GMMpneumatic servo valve has wide pressure control characteristics, good linearity, and fast responsespeed. The movement principles of the GMM robot system are reliably feasible and its maximal movingspeed is about 8 mm/s. It is preferable to the driving frequency of the robot within 100 approx 300Hz.

Simulation investigation on fluid characteristics of jet pipe water hydraulic servo valve based on CFD

Simulation investigation on fluid characteristics of the water hydraulic jet pipe servo valve （WHJPSV） is conducted through a commercial computational fluid dynamics （CFD） software package FLUENT. In particular, the factors to fluid characteristics of WHJPSV are addressed, which include diameter combination of jet pipe and receiver pipe, jet pipe nozzle clearance, angle between two jet receiver pipes and deflection angle of the jet pipe. It is concluded from the results that： （i） Structural parameters have great influences on fluid characteristics of WHJPSV, when d1 = d2 = 0.3 mm, α= 45 , b = 0.5 mm, and the simulation exhibits better fluid characteristics; （ii） The magnitude of the recovery pressure and flow velocity increase almost linearly with the deflection angle of jet pipe. The research work in this paper is important for determining and optimizing the structural parameters of the jet pipe and jet receiver. The relevant conclusions could be extended to the study of other water hydraulic servo control components.

Mathematical Model of Steady State Operation in Jet Pipe Electro-Hydraulic Servo Valve

Jet pipe electro-hydraulic servo valve is the heart of feedback control systems,and it is one of the mechatronic components used for precision flow control application.It consists of several precision and delicate components.The performance of the jet pipe servo valve depends on many parameters.During the developmental stage,it is very difficult to ascertain the function parameters.The steady-state analysis of jet pipe electro-hydraulic servo valve has been made to simulate its fluid characteristics(flowin,flow-out,leakage flow,recovery or load pressure,etc.)by mathematical modeling.Theoretical model was conducted on various affecting parameters on the pressure,the main flow rate of fluid,or leakage flow through the receiver holes.The major parameters studied are jet pipe nozzle diameters,receiver hole diameters,angle between the two centre-lines of receiver hole,nozzle offset,and nozzle stand-of distance.In this paper the research is important to determine and optimize the structural parameters of jet pipe servo valve.Thus,equations of the pressure and flow characteristics are set up and the optimal structural parameters of jet pipe are established.

Research on valve core’s clamping stagnation of double flapper-nozzle servo valve

Due to great changing of instantaneous temperature of hydraulic oil of double flapper-nozzle servo valve, thermal deformation between valve core and valve sleeve may result in catching phenomenon of valve core, and then the reliability of servo valve could be affected seriously. The work focuses on a particular model of double flapper-nozzle servo valve and establishes three dimension couple models of liquid-solid-thermal under extreme operating condition. The transmission route and dissipative mechanism of heat is revealed and thermal deformation behavior of valve core and valve sleeve is researched. A change law of the key fit clearance under the effect of thermal expansion and warp deformation is explored, the source of catching phenomenon of valve core is identified, and then preventive measure and improvement can be proposed. In order to verify the correctness of theoretical analysis, the moving smoothness of deformed valve core and reground valve core under the circumstance of high-temperature hydraulic oil on electrohydraulic servo valve static characteristics test table is compared and tested. The results show that as oil temperature rises, relative deformations between valve core and valve sleeve in different direction at a same cross-section are not equal, and then the key fit clearance is less than the initial value. Relative deformations in the same direction at different axial position are not equal, the deformations of middle and two ends are maximum and minimum values respectively, and then warp deformation of valve core occurs. When oil temperature is higher, the relative deformations between valve core and valve sleeve is larger, the moving smoothness of valve core gets worse, and the catching phenomenon of valve core occurs. Axial deformation of valve sleeve and valve core at different axial position is different, and the opening coefficient and stability of servo valve could be affected, especially the operation circumstance of small opening. The study can provide some guidance for designing double nozzle flapper servo valves.

Application of Modelica/MWorks on modeling,simulation and optimization for electro-hydraulic servo valve system

Electro-hydraulic servo valve is a typical complicated multi-domain system constituted by mechanical, electric, hydraulic and magnetic components, which is widely used in electro-hydraulic servo systems such as construction machinery, heavy equipment, weapon and so forth. The traditional method of modeling and simulation of servo valve is based on block diagram or signal flow, which cannot describe the servo valve system from components level nor be used in modeling and simulation of overall servo systems. In the procedure of traditional method, computational causality must be involved in modeling of servo valve, which is inconvenient to execute modification on components or parameters. Modelica is an object-oriented modeling language which is suited for large, complex, heterogeneous and multi-domain systems. The key features of Modelica are multi-domain, object-oriented and non-causal, which are suitable for modeling of servo valve and make the model readable, reusable, and easy to modify. The simulation results show similar curves with traditional method. This new servo valve modeling and simulation method can provide the engineers a more efficient way to design and optimize a servo valve and an overall servo system.

Simulation and experimental research of digital valve control servo system based on CMAC-PID control method

Digital valve control servo system is studied in this paper. In order to solve the system problems of poor control precision and slow response time,a CMAC-PID( cerebellar model articulation controller-PID) compound control method is proposed. This compound controller consists of two components: one is a traditional PID for the feedback control to guarantee stability of the system; the other is the CMAC control algorithm to form a feed-forward control for achieving high control precision and short response time of the controlled plant. Then the CMAC-PID compound control method is used in the digital valve control servo system to improve its control performance. Through simulation and experiment,the proposed CMAC-PID compound control method is superior to the traditional PID control for enhancing stability and robustness,and thus this compound control can be used as a new control strategy for the digital valve control servo system.

High precise control method for a new type of Piezoelectric electro-hydraulic servo valve

A new type of piezoelectric electro-hydraulic servo valve system was proposed. And then multilayer piezoelectric actuator based on new piezoelectric ceramic material was used as the electricity-machine converter of the proposed piezoelectric electro-hydraulic servo valve. The proposed piezoelectric electro-hydraulic servo valve has ascendant performance compared with conventional ones. But the system is of high nonlinearity and uncertainty, it cannot achieve favorable control performance by conventional control method. To develop an efficient way to control piezoelectric electro-hydraulic servo valve system, a high-precise fuzzy control method with hysteresis nonlinear model in feedforward loop was proposed. The control method is separated into two parts: a feedforward loop with Preisach hysteresis nonlinear model and a feedback loop with high-precise fuzzy control. Experimental results show that the hysteresis loop and the maximum output hysteresis by the PID control method are 4.22% and 2.11 μm, respectively; the hysteresis loop and the maximum output hysteresis by the proposed control method respectively are 0.74% and 0.37 μm, respectively; the maximum tracking error by the PID control method for sine wave reference signal is about 5.02%, the maximum tracking error by the proposed control method for sine wave reference signal is about 0.85%.

Dynamic Characteristics of the Jet Force on the Flapper of the Pilot Stage in a Flapper Nozzle Servo Valve Under the Flow-Solid Interaction

Nowadays,more and more attention has been paid to improve the performance of the nozzle flapper servo valve.As a core part of nozzle flapper servo valve,the armature assembly is affected by electromagnetic force,jet force and feedback force at the same time.Due to the complex structure of the pilot stage flow field and the high jet pressure,the prediction of the jet force has always been difficult in modeling the transient motion of the servo valve.Whereupon,a numerical simulation method based on the flow-solid interaction(FSI)is applied to observe the variation of the jet force when the flapper is moving.Different parameters are employed to seek a suitable numerical simulation model which can balance the accuracy and computational cost.By comparing with the experiment results,the effectiveness of numerical simulation method in predicting the variation of the jet force and cavitation is verified.By this numerical simulation model,the distribution of flow field and the force on the flapper predicted by the moving and fixed flapper are compared.The results show that more dynamic details are achieved by the transient simulation.By analyzing the numerical simulation results of different inlet pressures and flapper vibration frequencies,the relationship between the movement of the flapper,the flow field distribution,the jet force and the inlet pressure is established,which provides a theoretical basis for the subsequent modeling of the armature assembly.

ADAPTIVE CONTROLLER AND ITS APPLICATION IN FORCE SYSTEM OF ASYMMETRIC CYLINDER CONTROLLED BY SYMMETRIC VALVE

Partial pressure, system vibration and asymmetric system dynamic performance exit in asymmetric cylinder controller by symmetric valve hydraulic system. To solve this problem in the force control system, model reference adaptive controller is designed using equilibrium point stability theory and output error equation polynomial. The reference model is selected in such a way that it meets the system dynamic performance. Hardware configuration of asymmetric cylinder controlled by asymmetric valve hydraulic system is replaced by intelligent control algorithm, thus the cost is lowered and easy to application. Simulation results demonstrate that the proposed adaptive control sheme has good adaptive ability and well solves asymmetric dynamic performance problem. The designed adaptive controller is fairly robust to load disturbance and system parameter variation.

机械反馈式伺服阀流量测试动态缸参数选用分析

相比电反馈伺服阀动态特性可直接通过阀芯位移响应测试获得,机械反馈式流量伺服阀的动态特性,通常需利用动态缸作为流量传感器间接测量获得。测试结果受动态缸泄漏、阻尼、质量惯性等固有非理想化因素的影响,通常无法准确表达伺服阀本身的性能指标。基于一套实际阀控缸系统,建立Matlab-Simulink仿真模型,解析获得的频带宽结果相比实测结果误差小于0.5%,由此建立了可准确表达阀与缸性能特性的仿真模型。在此基础上,理论给出了伺服阀本身的频率特性指标,即无泄漏无阻尼及无限刚度动态缸条件下的系统频率特性。以此为依据,分析了实际动态缸活塞质量、活塞粘性阻尼以及泄漏变化情况下,阀控缸系统频率特性偏离理想条件的变化规律。

微小流量旋转直驱伺服阀传控特性分析与优化

针对无人机、战术弹、支线民航等小型飞行器航空发动机燃油计量系统与推力矢量系统微小流量的伺服控制需求,就旋转直驱伺服阀偏心球副传动接口与非全周节流阀口等关键结构进行了尺寸约束设计分析,并就节流阀口宽度、球副偏心距以及驱动电机转动惯量等重要参数进行了优化分析,给出了伺服阀结构设计的优化区间。在此基础上,研究提出了电机转角与电流双闭环控制方法,幅频响应实测结果与理论分析较为一致,200 Hz以上高频响应满足实际需求,且双闭环控制方法大幅降低了伺服阀响应超调并提升了稳定性。

电液伺服控制阀动态仿真与试验

电液伺服阀被广泛应用各种自动化装备中,这种复杂的机电控制系统集机、电、液、磁于一体,属于重要的随动跟踪控制元件,伺服控制除了有良好的静态性能外,其动力学特性决定了伺服系统工作精度.运用键合图理论建立电液伺服阀的键图模型;推导模型的状态空间方程和输出方程;运用仿真软件MATLAB/Simulink进行了仿真,分析电液伺服阀系统动态特性.最后在搭建的实验验证平台上验证了系统的动态性能,并与仿真结果进行了比较分析.结果是该电液伺服阀的动态特性指标超调量40%、响应时间13ms、上升时间2ms左右.

伺服阀产线的智能协议转换技术研究

针对多源异构设备数据之间互联互通的实际需求,提出了一种多源数据智能协议转换技术。以数据协议为核心,将采集的信息来源对象化后导入协议解析数据库,归一化后,基于不同应用需求的重构协议,如OPC UA(OPC Unified Architecture),输出XML(Extensible Markup Language)文件或存储至服务器,最后将数据库接入到产线的数据集成管控系统进行数据分析和可视化展示。以民机伺服阀产线产品调试设备为研究对象,采集油源、测试台和试验箱等设备状态和运行参数,对提出的数据协议转换技术进行了验证。实验证明,所提出的方法实现了油源、测试台和试验箱等设备数据之间的互联互通,为多源异构设备数据采集的融合应用提供了基础。