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

PRESSURE COMPENSATION METHOD OF UNDERWATER HYDRAULIC SYSTEM WITH HYDRAULIC POWER UNIT BEING UNDER ATMOSPHERIC CIRCUMSTANCE AND PRESSURE COMPENSATED VALVE

Based on the analysis of the-state-of-the-art of pressure compensation of underwater hydraulic systems （UHSs）, a new method of pressure compensation of UHSs, whose hydraulic power unit is in the atmospheric circumstance, is proposed. And a pilot-operated relief valve with pressure compensation is realized. The pressure compensation precision is guaranteed by direct detection. Its dynamic performance and stability are improved by a dynamic feedback. Theoretical study, simulation and experiment show that the pilot-operated relief valve with pressure compensation has a fine property of tracking underwater ambient pressure and meet the requirement of underwater ambient pressure compensation.

Design of a 70 MPa Two-Way Proportional Cartridge Valve for Large-Size Hydraulic Forging Press

For an ultra-high-pressure hydraulic transmission system of a large-size hydraulic forging press(LHFP),a 70 MPa two-way proportional cartridge valve has been developed to improve the power weight ratio of the hydraulic forging press.In this study,a nominal diameter 25 mm(DN25)cartridge valve is taken as the research object.A longer concentric cylindrical annular gap is set to effectively prevent the ultra-high-pressure oil from flowing to the pilot stage and a seated valve structure is set to form the linear sealing zone in the closing state of the main valve port.Electric-displacement feedback is adopted to realize precise control of the main valve port flow and the features of this valve are investigated.In order to verify the strength and static and dynamic characteristics,the finite element model and a simulation model of the valve proposed above are built.There is a little deformation which does not affect the main valve spool movement,and the main valve port flow meets the design demands.Then,the prototype of DN2570 TPCV is manufactured and a ultra-high-pressure experimental platform is developed.The experimental results show that the DN2570 TPCV designed in this study has the advantage of fast response,high control precision,and low leakage,which can meet the requirements of LHFPs.

Numerical investigation of cavitating flow behind the cone of a poppet valve in water hydraulic system

Computational Fluid Dynamics (CFD) simulations of cavitating flow through water hydraulic poppet valves were performed using advanced RNG k-epsilon turbulence model. The flow was turbulent, incompressible and unsteady, for Reynolds numbers greater than 43 000. The working fluid was water, and the structure of the valve was simplified as a two dimensional axisymmetric geometrical model. Flow field visualization was numerically achieved. The effects of inlet velocity, outlet pressure, opening size as well as poppet angle on cavitation intensity in the poppet valve were numerically investigated. Experimental flow visualization was conducted to capture cavitation images near the orifice in the poppet valve with 30° poppet angle using high speed video camera. The binary cavitating flow field distribution obtained from digital processing of the original cavitation image showed a good agreement with the numerical result.

Closed Loop Hydraulic System and Its Effect on Actuator Design

Hydraulic systems provide a clean and stable supply of hydraulic fluid for subsea valves and actuators installed on the subsea bed in subsea production systems.Subsea control systems are used for contemporary subsea fields instead of installing the control system on topside.Although all-electric subsea systems are state-of-the-art with benefits such as health,safety,and environment improvement,as well as efficiency and lower cost,hydraulic systems are still used for the development of many subsea fields.One of the main questions in the selection of a subsea hydraulic field is whether to choose an open or closed loop hydraulic system.The main characteristic of an open loop hydraulic system is that the hydraulic fluid is discharged into the marine environment during the actuation of the subsea valves.Conversely,the hydraulic fluid is returned to the topside facilities through an umbilical system in a closed loop system.Given that closed loop systems are more eco-friendly,the main question in this research is to examine the effect of the actuator connection of the closed loop system on actuator design.Two cases of actuated valves connected to a closed loop system are analyzed in this paper.The first is a 71/16-in.subsea slab gate valve in the pressure class of 517 bar with a linear spring return fail-safe close(FSC)actuator located on a manifold branch.The data indicates that the piston rod and cylinder diameter of the FSC linear actuator should be increased by some millimeters due to the accumulation of hydraulic oil at the bottom of the actuator.The hydraulic oil in the closed loop system helps in closing the actuator and spring force,so the spring constant and torque should be reduced as a result.The second case involves a 16-in.subsea ball valve in the pressure class of 517 bar with a double-acting fail-as-is rack and pinion actuator.The conclusion in this case is to avoid making any change in the design of double-acting actuator in connection to the closed loop system.

Experimental Verification of Fault Predictions in High Pressure Hydraulic Systems

In this paper a model of a high pressure hydraulic system was developed to simulate the effect of increased internal leakages inside the hydraulic cylinder and the 4/2 way directional control valve and to calculate the main parameters of the hydraulic system under various loads through the use of leakage-simulating throttle valves. After the completion of modeling, the throttle valves that simulate the internal leakages were calibrated and a number of test runs were performed for the cases of normal operation and the operation with increased internal leakages. The theoretical predictions were compared against the experimental results from an actual hydraulic test platform installed in the laboratory. In all cases, modeling and experimental data curves correlate very well in form, magnitude and response times for all the system’s main parameters. This proves that the present modeling can be used to accurately predict various faults in hydraulic systems, and can thus be used for proactive fault finding in many cases, especially when the defective component is not easily detected and obvious at first sight.

Numerical Simulation on a Throttle Governing System with Hydraulic Butterfly Valves in a Marine Environment

Hydraulic butterfly valves have been widely applied in marine engineering because of their large switching torque, low pressure loss and suitability for large and medium diameter pipelines. Due to control problems resulting from switching angular speeds of the hydraulic butterfly valve, a throttle-governing control mode has been widely adopted, and detailed analysis has been carried out worldwide on the structural principle concerning speed-regulation and the load torque on the shaft while opening or closing a hydraulic butterfly valve. However relevant reports have yet been published on the change law, the error and the influencing factors of the rotational angular velocity of the hydraulic butterfly valve while opening and closing. In this article, research was based on some common specifications of a hydraulic butterfly valve with a symmetrical valve flap existing in a marine environment. The throttle governing system supplied by the accumulator to achieve the switching of the hydraulic control valve was adopted, and the mathematical models of the system were established in the actual conditions while the numerical simulations took place. The simulation results and analysis show that the rotational angular velocity and the error of the hydraulic butterfly valve while switching is influenced greatly by the drainage amount of the accumulator, resulting in pressure loss in the pipeline, the temperature of hydraulic medium and the load of the hydraulic butterfly valve. The simulation results and analysis provide a theoretical basis for the choice of the total capacity of the accumulator and pipeline diameters in a throttle governing system with a hydraulic butterfly valve.It also determines the type and specification of the hydraulic butterfly valve and the design of motion parameters of the transported fluid.

Dynamic Simulation and Valve Structure Optimization of an Electro-Hydraulic Clutch Shift Control System in an Automatic Transmission

The electro-hydraulic clutch control system controls the transferred torque of gear-shifting clutches in clutch-to-clutch transmissions. A nonlinear dynamic model of an electro-hydraulic clutch shift control system is presented. The mechanical and fluid subsystems of all valves are investigated, including their interactions. Model validation of the electro-hydraulic valve system is performed by comparing the simulated and measured pressure curves. The dynamic characteristics of the electro-hydraulic clutch shift control system with different supply pressures and different fluid temperatures are simulated and evaluated. It is found that pipes which are often ignored between the electro-hydraulic valve system and the clutch piston,have strong influence on clutch piston chamber pressures. In order to satisfy the required time and reduce the fluctuation of the clutch piston chamber pressures,the orifices' diameters and valve structure are optimized.

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.

Lateral Force Characteristics of Cartridge Valve Core

The flow field of eccentric conical crevices is formed into the working process of hydraulic valves.Therefore, the valve core is readily subjected to a large lateral force which affects the dynamic response speed.Here, a new type of cartridge valve core structure is proposed to solve this problem. The numerical simulationmethod is applied to analyze the flow characteristics of clearance flow field on velocity distribution, pressuredistribution, valve core motion speed, and leakage. The results using computational fluid dynamics (CFD) showthat the guide groove is set on the surface of the cartridge valve core, increasing the connecting length of thevalve core, forming a uniform radial pressure distribution and velocity distribution, effectively reducing the lateralforce, and at the same time ensuring that the leak is not too big. These findings provide theoretical guidance anda basis for optimizing cartridge valve to reduce the occurrence of jamming and improve the response frequency.

Output Waveform Analysis of an Electro-hydraulic Vibrator Controlled by the Multiple Valves

The existing research of the electro-hydraulic vibrator mainly focuses on system stability, working frequency width and output waveform distortion. However, this high frequency performance of the electro-hydraulic vibrator is difficult to be improved greatly due to fast insufficiently frequency response of the servo valve itself and limited compensation capability of the control structure in the vibrator system. In this paper, to realize high frequency vibration, an improved two-dimensional valve （here within defined as a 2D valve） as a main control component is adopted to the parallel connection with a servo valve to control the electro-hydraulic vibrator, Because the output waveforms of this electro-hydraulic vibrator are incapable to be verified through timely feedback as in the conventional electro-hydraulic servo system, the analysis to the output waveform becomes crucial to the design and control of the electro-hydraulic vibrator. The mathematical models of hydraulic actuation mechanism and the orifice area of the parallel valves connection are established first. And then the vibration process is divided into two sections in terms of the direction of the flow, the analytical expression of the excited waveform is solved. Based on relationships exist between working states and the control parameters the analytical results, the vibration boundary positions and the are derived. Finally an experimental system was built to validate the theoretical analysis. It is verified that this electro-hydraulic vibration system could achieve high working frequency, up to 2 000 Hz. The excited waveform is similar to the sinnsoidal waveform. And the ascent and decent slopes of the waveforms are somewhat asymmetrical. This asymmetry is not only caused by the change of the direction of the elastic force but also dependent on the bias position of the vibration. Consequentky the distortion of effective working waveform is less tha~ 10%. This electro-hydraulic vibrator controlled by the multiple valves could not only greatly enhance the working frequency but also precisely control the vibration characteristic variables such as waveform shape.

Research and Development of Electro‑hydraulic Control Valves Oriented to Industry 4.0:A Review

Electro-hydraulic control valves are key hydraulic components for industrial applications and aerospace,which controls electro-hydraulic motion.With the development of automation,digital technology,and communication technology,electro-hydraulic control valves are becoming more digital,integrated,and intelligent in order to meet the requirements of Industry 4.0.This paper reviews the state of the art development for electro-hydraulic control valves and their related technologies.This review paper considers three aspects of state acquisition through sensors or indirect acquisition technologies,control strategies along with digital controllers and novel valves,and online maintenance through data interaction and fault diagnosis.The main features and development trends of electro-hydraulic control valves oriented to Industry 4.0 are discussed.

EXPERIMENTAL INVESTIGATIONS OF CAVITATION EFFECTS ON FLOW CHARACTERISTICS OF SMALL ORIFICES AND VALVES IN WATER HYDRAULICS

The flow characteristics and cavitation effects of water passing throughsmall sharp-edged cylindrical orifices and valves of different shapes in water hydraulics areinvestigated. The test results using orifices with different aspect ratios and different diametersshow that the flow coefficients in the case of non-cavitating flow are larger than that of flow inthe case of cavitation occurrence. The flow coefficients of flow with cavitation initially decreaseas Reynolds number increases and ultimately tend to be of constant values close to contractioncoefficient. Large aspect ratio has an effect of suppressing cavitation. The experimental resultsabout disc valves illustrate that the valves with sharp edge at large opening are less affected bycavitation than that at small opening. Throttle with triangle notch has better anti-cavitationability than that with square notch. The flowrate of the throttle with square notch is significantlyaffected by the flow direction or the flow passage shape.

High Speed On/Off Valve Control Hydraulic Propeller

The work-class remotely-operated-underwater-vehicles（ROVs） are mainly driven by hydraulic propulsion system,and the effeciency of hydraulic propulsion system is an important performance index of ROVs.However,the efficiency of traditional hydraulic propulsion system controlled by throttle valves is too low.Therefore,in this paper,for small and medium ROVs,a novel propulsion system with higher efficiency based on high speed on/off valve control hydraulic propeller is proposed.To solve the conflict between large flow rate and high frequency response performance,a two-stage high speed on/off valve-motor unit with large flow rate and high response speed simultaneously is developed.Through theoretical analysis,an effective fluctuation control method and a novel pulse-width-pulse-frequency-modulation（PWPFM） are introduced to solve the conflict among inherently fluctuation,valve dynamic performance and system efficiency.A simulation model is established to evaluate the system performance.To prove the advantage of system in energy saving,and test the dynamic control performance of high speed on/off valve control propeller,a test setup is developed and a series of comparative experiments is completed.The smimulation and experiment results show that the two-stage high speed on/off valve has an excellent dynamic response performance,and can be used to realize high accuracy speed control.The experiment results prove that the new propulsion system has much more advantages than the traditional throttle speed regulation system in energy saving.The lowest efficiency is more than 40%.The application results on a ROV indicate that the high speed on/off valve control propeller system has good dynamic and steady-state control performances.Its transient time is only about 1 s-1.5 s,and steady-state error is less than 5%.Meanwhile,the speed fluctuation is small,and the smooth propeller speed control effect is obtained.On the premise of good propeller speed control performance,the proposed high speed on/off valve control propeller can improve the effeciency of ROV propulsion system significantly,and provides another attractive ROV propulsion system choice for engineers.

Thermal-hydraulic modeling and analysis of spool valve with sloping U-shape notch by bond graph

To increase the efficiency and reliability of the thermodynamics analysis of the spool valve, the precise function expression of the flow area for the sloping U-shape notch orifice versus the spool stroke and thermal-hydraulic bond graph based on the conservation of mass and energy were introduced. Subsequently, the connection rule for the bond graph elements and the method to construct the complete thermal-hydraulic system model were proposed. On the basis of heat transfer analysis of a typical hydraulic circuit containing the spool valve, the lumped parameter for mathematical model of the system was given. At last, the reliability of the mathematical model of the flow area and the thermal-hydraulic system for the sloping U-shape notch orifice on the spool were demonstrated by the test. The good agreement between the simulation results and experimental data demonstrates the validity of the modeling method.

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.

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.

Fluid structure interaction for circulation valve of hydraulic shock absorber

Based on the working principle and the damping characteristic of hydraulic shock absorber, a fluid structure interaction method was presented, which was used to analyze the microcosmic and high-frequency processing mechanism of fluid structure interaction between circulation valve and liquid of hydraulic shock absorber. The fluid mesh distortion was controlled by the CEL language, and the fluid struc^tre interaction mathematical model was established. The finite element model was established by ANSYS CFX software and was analyzed by dynamic mesh technique. The local sensitive computational area was meshed by prismatic grid, which could reduce the negative volume problem during the simulation. The circulation valve and liquid of hydraulic shock absorber were simulated and analyzed under the condition of sinusoidal inlet velocity loads. Flow characteristic and dynamics characteristic were obtained. The pressure distribution and the displacement of circulation value were obtained, and the acceleration curve of circulation valve was simulated and analyzed. The conformity of the final simulation results with the experimental datum indicates that this method is accurate and reliable to analyze the dynamics characteristic between circulation valve and liquid of hydraulic shock absorber, which can provide a theoretical foundation for optimizing hydraulic shock absorber in the future.

Dynamic Modelling and Design of a Servomechanism for Hydraulic Directional-Control Valves

This paper analyses a control strategy applicable in heaVy-duty hydraulic Systems,namely, the introduction of a servovalve to achieve smoother operation of direCtional-control valves that serve also as flow-control valves over two fanges of operating conditions. A mathematical model of the dynamics of the System is etallished and design criteria are obtained from a linearised form of that model. The influence of variations in tile axial force on the spool of the main valve is investigated, and the use of the resultS in the design of systems of the proposed kind is discussed.

Research of vibrations effect on hydraulic valves in military vehicles

The paper discusses minimizing the effect of external mechanical vibration on hydraulic valves in different military hydraulic drive systems.The current research work presents an analysis of the potential to reduce vibration on the valve casing by installing a valve flexibly on a vibrating surface,i.e.,by introducing a material with known stiffness and damping characteristics between the valve casing and the vibrating surface-a steel spring package or special cushions made of elastomer material or of oilresistant rubber.The article also demonstrates that elastomer cushions placed inside the valve casingbetween the casing and the centering springs-can be used as a supplementary or alternative solution in the analyzed method for mitigating the transfer of vibrations.By using materials with appropriately selected elastic and dissipative properties,the effectiveness of vibro-isolation can be increased.The presented theoretical analyzes by linear and non-linear mathematical models have been verified experimentally.