Displacement Controlled Fluid Power System with Flow Sharing Capabilities Robert Andersson Mikael Axin Division of Fluid and Mechanical Engineering Systems Master Thesis Department of Management and Engineering LIU-IEI-TEK-A- -09/00577- -SE Displacement Controlled Fluid Power System with Flow Sharing Capabilities Master Thesis in Fluid Power Department of Management and Engineering Division of Fluid and Mechanical Engineering Systems Linköping University by Robert Andersson Mikael Axin LIU-IEI-TEK-A- -09/00577- -SE Supervisors: Björn Eriksson IEI, Linköping University Daniel Sundkvist Parker Hannifin AB Examiner: Karl-Erik Rydberg IEI, Linköping University Linköping, 26 February, 2009 Datum 2009-02-26 Date Avdelning, Institution Division, Department Institutionen för ekonomisk och industriell utveckling Fluid och mekanisk systemteknik Department of Management and Engineering Fluid and Mechanical Engineering Systems Språk Language Rapporttyp Report category ISBN Svenska/Swedish Licentiatavhandling ISRN Engelska/English Examensarbete C-uppsats D-uppsats Övrig rapport — LIU-IEI-TEK-A- -09/00577- -SE Serietitel och serienummer ISSN Title of series, numbering — URL för elektronisk version http://www.ep.liu.se Titel Title Displacement Controlled Fluid Power System with Flow Sharing Capabilities Författare Robert Andersson Author Mikael Axin Sammanfattning Abstract The purpose of this master thesis is to further develop a displacement controlled fluid power system. It uses similar components as a load sensing system but the pump is controlled in a different way. Instead of a pressure closed loop control mode the pump operates in an open control mode where the requested displacement is set by the operator. This principle might imply higher energy efficiency, faster response and less oscillations. If the pump is displacement controlled and the valve is equipped with common pre compensators the flow delivered from the pump needs to be matched by the valve. A flow map would then be required and problems might occur if incorrect flow is delivered by the pump. A solution to the problem is to utilize pre compensators with anti saturation. The flow will then be shared proportionally to the active actuators and no flow map is needed. Since the compensators will make sure that all flow will reach the actuators the main spool can be manoeuvred to its end position, which allows additional energy savings. The displacement controlled system has been designed and simulated using the simulation software AMESim. All components in the system have been modelled and validated using a laboratory platform. The system has also been implemented in a wheel loader application where it can be compared to a load sensing system. Measurements confirm that the energy efficiency is higher in a displacement controlled system compared to a load sensing system during a short duty cycle. Nyckelord Keywords Energy efficiency, pump pressure margin, compensation, displacement control Abstract The purpose of this master thesis is to further develop a displacement controlled fluid power system. It uses similar components as a load sensing system but the pump is controlled in a different way. Instead of a pressure closed loop control mode the pump operates in an open control mode where the requested displacement is set by the operator. This principle might imply higher energy efficiency, faster response and less oscillations. If the pump is displacement controlled and the valve is equipped with common pre compensators the flow delivered from the pump needs to be matched by the valve. A flow map would then be required and problems might occur if incorrect flow is delivered by the pump. A solution to the problem is to utilize pre compensators with anti saturation. The flow will then be shared proportionally to the active actuators and no flow map is needed. Since the compensators will make sure that all flow will reach the actuators the main spool can be manoeuvred to its end position, which allows additional energy savings. The displacement controlled system has been designed and simulated using the simulation software AMESim. All components in the system have been modelled and validated using a laboratory platform. The system has also been implemented in a wheel loader application where it can be compared to a load sensing system. Measurements confirm that the energy efficiency is higher in a displacement controlled system compared to a load sensing system during a short duty cycle. v Acknowledgments This master thesis has been written at Parker Mobile Systems Team in Borås. We would like to thank the whole department for their time and effort. Our supervisor Daniel Sundkvist can always spare a moment for discussions and he has allowed us to go our own way during this master thesis. Anders Eliasson has helped us a lot with the laboratory platform and the test rig. When it comes to technical issues, Anders Lindström has been of great help. We would also like to thank Per-Anders Kumlin at Parker Mobile Control Division. Because of his master thesis and especially the construction of the test rig, our work became a lot easier. Our supervisor at the university has been Björn Eriksson. He has helped us a lot in almost all possible ways, especially with problem regarding the report. He has also been involved in the simulation and the system design. Finally, we would like to thank our examiner Karl-Erik Rydberg and our opponent Karl Pettersson. Linköping, February, 2009 Robert Andersson Mikael Axin vii Contents 1 Introduction 1.1 Background . . 1.2 Purpose . . . . 1.3 Delimitations . 1.4 Method . . . . 1.5 Report Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 7 7 8 8 9 2 Basic Theory 2.1 Mobile Fluid Power Systems . . . . . . . . . . . 2.1.1 Constant Flow . . . . . . . . . . . . . . 2.1.2 Constant Pressure . . . . . . . . . . . . 2.1.3 Load Sensing . . . . . . . . . . . . . . . 2.2 Pressure Compensation . . . . . . . . . . . . . 2.2.1 Common Pre Compensation . . . . . . . 2.2.2 Pre Compensation with Anti Saturation 2.2.3 Post Compensation . . . . . . . . . . . . 2.3 Displacement Controlled System . . . . . . . . 2.3.1 Flow Mapping . . . . . . . . . . . . . . 2.3.2 Compensation . . . . . . . . . . . . . . 2.3.3 Energy Savings . . . . . . . . . . . . . . 2.4 Flow Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 11 11 12 12 13 13 14 16 17 17 17 17 18 3 Design of Simulation Models 3.1 Pump . . . . . . . . . . . . . . . . 3.1.1 Pressure Control . . . . . . 3.1.2 Displacement Control . . . 3.2 Valve . . . . . . . . . . . . . . . . . 3.2.1 Cartridge Valve . . . . . . . 3.2.2 Main Spool . . . . . . . . . 3.2.3 Common Pre Compensator 3.2.4 Pre Compensator with Anti 3.2.5 ∆pp Limiter . . . . . . . . . 3.3 Actuator . . . . . . . . . . . . . . . 3.4 Load Sensing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 21 23 23 26 26 28 30 33 36 37 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Saturation . . . . . . . . . . . . . . . . . . . . . x Contents 3.5 Displacement Controlled Systems . . . . . . . . . . . . . . . . . . . 4 Validation of Simulation Models 4.1 Laboratory Platform . . . . . . 4.1.1 ∆p/q Test . . . . . . . . 4.1.2 Flow Forces . . . . . . . 4.1.3 Step Response . . . . . 4.2 Test Rig . . . . . . . . . . . . . 4.2.1 Pump . . . . . . . . . . 4.2.2 Load Pressure Feedback 4.2.3 Pressure Losses . . . . . 4.3 Load Sensing Systems . . . . . 4.3.1 Pump Saturation . . . . 4.3.2 Step Response . . . . . 40 . . . . . . . . . . . . . . . . . . . . . . 43 43 45 45 47 47 49 49 50 51 51 53 5 Design of Displacement Controlled Systems 5.1 Flow Mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.1 Valve Control . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.2 Pump Control . . . . . . . . . . . . . . . . . . . . . . . . 5.2 System Characteristics . . . . . . . . . . . . . . . . . . . . . . . . 5.2.1 Response Behaviour . . . . . . . . . . . . . . . . . . . . . 5.2.2 Dynamic Stability . . . . . . . . . . . . . . . . . . . . . . 5.2.3 System Pressure . . . . . . . . . . . . . . . . . . . . . . . 5.3 Incorrect Flow Delivery . . . . . . . . . . . . . . . . . . . . . . . 5.3.1 Not Enough Flow is Delivered . . . . . . . . . . . . . . . . 5.3.2 Too Much Flow is Delivered . . . . . . . . . . . . . . . . . 5.4 Displacement Controlled System with Flow Sharing Capabilities 5.4.1 One Actuator . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.2 Two Actuators . . . . . . . . . . . . . . . . . . . . . . . . 5.4.3 Flow Forces . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.4 Position Feedback . . . . . . . . . . . . . . . . . . . . . . 5.4.5 Different Loads . . . . . . . . . . . . . . . . . . . . . . . . 5.4.6 Redesign of the Flow Sharing Compensator . . . . . . . . 5.4.7 Lowering Motion . . . . . . . . . . . . . . . . . . . . . . . 5.4.8 Cylinder is Unable to Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 56 56 57 58 58 58 58 59 60 61 62 63 64 65 66 66 68 69 70 6 System Improvements - Verifying Measurements 6.1 Pump Pressure Margin Reduction . . . . . . . . . 6.2 Pump Saturation . . . . . . . . . . . . . . . . . . . 6.3 Step Response . . . . . . . . . . . . . . . . . . . . 6.4 Short Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . 71 71 73 74 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Summary & Conclusions 81 8 Future Work 83 Bibliography 85 A Hydraulic Schematic of a L90LS Valve 87 xii Contents Contents 1 List of Figures 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 Constant flow power figure . . . . . . . . . Constant pressure power figure . . . . . . . Load sensing power figure . . . . . . . . . . Common pre compensators [5] . . . . . . . Pre compensators with anti saturation [5] . Post compensators [5] . . . . . . . . . . . . Dispacement controlled system power figure Flow forces acting on a spool [4] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 12 13 14 15 16 18 18 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 P1 pump controller [5] . . . . . . . . . . . . . . . . . . . . . . . . . Simulation model of a pressure controlled pump . . . . . . . . . . . Simulation model of a displacement controlled pump . . . . . . . . L90LS valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure reducer and cartridge valve . . . . . . . . . . . . . . . . . Simulation model of the cartridge valve . . . . . . . . . . . . . . . Main spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Restriction area for the main spool . . . . . . . . . . . . . . . . . . Simulation model of the main spool . . . . . . . . . . . . . . . . . Pre compensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . Restriction area for a common pre compensator . . . . . . . . . . . Simulation model of a pre compensator . . . . . . . . . . . . . . . Pre compensator with anti saturation . . . . . . . . . . . . . . . . Restriction area for a pre compensator with anti saturation . . . . Simulation model of a pre compensator with anti saturation . . . . Simulation model of a ∆pp limiter . . . . . . . . . . . . . . . . . . Simulation model of an actuator . . . . . . . . . . . . . . . . . . . A load sensing system with common pre compensators . . . . . . . A load sensing system with pre compensators with anti saturation A displacement controlled system with common pre compensators A displacement controlled system with flow sharing capabilities . . 22 24 25 26 27 28 29 29 31 32 32 33 34 34 36 36 37 38 39 40 41 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 Setup during laboratory tests . . . . . . . . . . . . . . . . . . . . . Plugged connection between lspb and t2b/t3b . . . . . . . . . . . ∆p/q test using common pre compensators . . . . . . . . . . . . . ∆p/q test using pre compensators with anti saturation . . . . . . . The influence of flow forces . . . . . . . . . . . . . . . . . . . . . . The affects of flow forces in laboratory and simulation . . . . . . . Main spool step response . . . . . . . . . . . . . . . . . . . . . . . Zettelmeyer 802 Si [5] . . . . . . . . . . . . . . . . . . . . . . . . . P1 pump validation . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure build up in the load pressure feedback pipe . . . . . . . . Pressure losses in the pipe connecting the pump and the valve . . . A saturated situation with common pre compensators in the test rig A saturated situation with common pre compensators in simulation 44 44 45 46 46 47 47 48 49 50 51 52 52 2 Contents 4.14 A saturated situation with pre compensators with anti saturation . 4.15 Step response made in the test rig . . . . . . . . . . . . . . . . . . 4.16 Step response made in the simulation model . . . . . . . . . . . . . 53 54 54 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 Displacement controlled system [5] . . . . . . . . . . . . . . . . . Flow field when using common pre compensators . . . . . . . . . Load sensing and displacement controlled power figure . . . . . . System characteristics when not enough flow is delivered . . . . . System characteristics when too much flow is demanded . . . . . Flow field when using pre compensators with anti saturation . . Flow field when manoeuvring the main spool to its end position . ∆p controls the flow . . . . . . . . . . . . . . . . . . . . . . . . . Two actuators with different flow demand . . . . . . . . . . . . . Two actuators affected by flow forces . . . . . . . . . . . . . . . . Two actuators controlled by a position feedback . . . . . . . . . . Two actuators with compensator in its end position . . . . . . . . Two actuators with different loads and decreased restriction area Redesign of the quota . . . . . . . . . . . . . . . . . . . . . . . . Redesign of the quota and the maximal restriction area . . . . . Two actuators with different loads and a redisigned compensator . . . . . . . . . . . . . . . . 55 57 59 60 61 62 63 64 65 65 66 67 68 68 69 69 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16 6.17 6.18 Pump pressure margin in a load sensing system . . . . . . . Pump pressure margin in a displacement controlled system Pump saturation in a load sensing system . . . . . . . . . . Pump saturation in a displacement controlled system . . . . Step response in a load sensing system . . . . . . . . . . . . Step response in a displacement controlled system . . . . . Step response in both systems . . . . . . . . . . . . . . . . . Short duty cycle [3] . . . . . . . . . . . . . . . . . . . . . . . Command signals using a load sensing system . . . . . . . . Actuator positions using a load sensing system . . . . . . . Pump- and load pressure using a load sensing system . . . . Pump pressure margin using a load sensing system . . . . . Command signals in a short duty cycle . . . . . . . . . . . . Actuator positions in a short duty cycle . . . . . . . . . . . Pump- and load pressure in a short duty cycle . . . . . . . Pump pressure margin in a short duty cycle . . . . . . . . . Power consumption in a short duty cycle . . . . . . . . . . . Energy consumption in a short duty cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 72 73 73 74 74 75 75 76 76 77 77 78 78 78 78 79 79 7.1 Pump pressure margin in load sensing and displacement controlled 82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contents 3 List of Tables 4.1 4.2 Measured parameters in the laboratory tests . . . . . . . . . . . . . Measured parameters in the test rig . . . . . . . . . . . . . . . . . 44 48 4 Contents Nomenclature Ac Ac,max Ac1 Ac2 As As,allowed As,max c Cq d Dp F0 Fs Fs k l L np p p1 p2 pl pl,max po pp pr P q qc qin qout qp Compensator restriction area Maximal compensator restriction area Compensator area exposed to control pressure Compensator area exposed to control pressure Main spool restriction area Maximal allowed main spool restriction area Maximal main spool restriction area Speed of sound in oil Flow coefficient Diameter Pump displacement Preload spring force Spring force Flow force Spring stiffness Length Length Pump shaft speed Pressure Upstream pressure Downstream pressure Load pressure Maximal load pressure Pressure reduced by the main orifice Pump pressure Pressure reduced by the compensator Power Flow Flow across the compensator Flow into a volume Flow out of a volume Pump flow 5 [m2 ] [m2 ] [m2 ] [m2 ] [m2 ] [m2 ] [m2 ] [m/s] [−] [m] [m3 /rev] [N ] [N ] [N ] [N/m] [m] [m] [rev/s] [P a] [P a] [P a] [P a] [P a] [P a] [P a] [P a] [W ] [m3 /s] [m3 /s] [m3 /s] [m3 /s] [m3 /s] 6 Contents qs t twave v V w xc xs βe δ ∆pf ∆pp ∆ps εp ηvol,p λ ρ Flow across the main spool Time Time for a wave to travel across a volume Velocity Volume Area gradient Compensator spool position Main spool position Effective bulk modulus Jet angle Pressure losses Pump pressure margin Pressure difference across the main spool Pump cam position Volumetric efficiency of the pump Friction factor Density [m3 /s] [s] [s] [m/s] [m3 ] [m] [m] [m] [P a] [ ◦] [P a] [P a] [P a] [−] [−] [−] [kg/m3 ] Chapter 1 Introduction 1.1 Background Mobile fluid power applications of today consume more energy than necessary to achieve useful work. Since there are future demands for lower fuel consumption, more energy efficient systems need to be developed. When energy efficiency is a vital issue load sensing systems are frequently utilized. Therefore it is appropriate to compare new system proposals with a load sensing system. Most fluid power systems still utilize mechanical control. But as electric control becomes more common the system design has got new possibilities. Both pump and valve could be controlled electronically which allows new control strategies. One way is to control the displacement of the pump instead of the pressure, which is done in a load sensing system. An earlier master thesis at Parker Hannifin [5] has shown that it is possible to design a displacement controlled system using similar components as in a load sensing system and improve the energy efficiency. However, this type of system design raises new control problems that need to be solved in order to guarantee the system operability under all circumstances. 1.2 Purpose In the previous master thesis a displacement controlled system was implemented in a wheel loader application. Although it worked reasonably well there was insufficient knowledge of the system characteristics. In order to further develop the displacement controlled system such knowledge is a necessity. The purpose of this master thesis is therefore to gain knowledge about the system characteristics in order to make further developments. An investigation regarding further improvement of the energy efficiency should also be made. 7 8 1.3 Introduction Delimitations When discussing about energy efficiency in this master thesis, it is the working hydraulics that is referred to. Neither the steering nor the transmission has been taken under consideration. When designing displacement controlled systems, it might not be necessary to utilize a load sensing pressure compensated directional valve. However, in this master thesis no other opportunities have been taken under consideration. The theory about post compensated valves is included in this master thesis but further investigations have not been made. This is partly because only a pre compensated valve was available in the test rig. In the simulation models the leakage has been neglected. The simulation models are only used for comparison and in that point of view the leakage will not have any influence. 1.4 Method The chosen approach when developing the displacement controlled system is simulation. In a simulation environment all parameters can be measured and a very good overview of the system is obtained. AMESim is the chosen simulation software in this master thesis. The software is based on components representing real physical models and is therefore simple to use and the models easy to overview. The program comes with standard libraries containing among other things hydraulic components. When designing simulation models it is necessary to compare the simulation results with measurements made on real components. In order to validate the simulation models a laboratory platform as well as a test rig has been used. To get a good reference, a load sensing system is built using the validated simulation models. The test rig can then be used to achieve proper system characteristics in the simulation model of the load sensing system. Since the displacement controlled system consist of similar components as the load sensing system, it can be used when developing the displacement controlled system. Behaviours that hardly can be noticed otherwise can be detected while simulating and adjustment can be made. When comparing the displacement controlled system with a load sensing system regarding energy efficiency it is not reliable to use the simulation models. Instead a wheel loader application is used in order to get a proper comparison. Because the final comparison is not made in the simulation software the models can be made fairly simple and only the dynamics of interest are taken under consideration. The models are in some cases made in a general way in order to get an easy comparison. Therefore the simulation models should not be seen as an exact image of the real components but more as a tool to compare different system designs. 1.5 Report Outline 1.5 9 Report Outline The second chapter consists of basic theories about common fluid power systems. Different pressure compensators used in load sensing systems are also explained. The reader is then introduced to a displacement controlled system and the concept of flow forces. In the third chapter the design of all simulation models will be explained, at first separately and then together in load sensing- and displacement controlled systems. In the fourth chapter all simulation models will be validated. Both a laboratory platform and a test rig are utilized. Some important characteristics in load sensing systems are also validated. These systems will later be used as a reference when designing new types of systems. The fifth chapter will explain how displacement controlled systems could be designed. Control strategies and the characteristics of the system are discussed. Simulation models are used to confirm the discussions and finally a new system proposal is introduced. In the sixth chapter a load sensing system and the new system proposal are compared in a wheel loader application. The performance and the energy efficiency are considered. The seventh and eighth chapter consists of a summary, some conclusions and future work. 10 Introduction Chapter 2 Basic Theory 2.1 Mobile Fluid Power Systems This is a short summary of the most common fluid power systems that is used today and their power characteristics. All of the systems have their advantages and disadvantages. A system that is suitable in one application can be useless in another. To understand the power comparison between the systems it is important to know the relation between pressure, flow and power, see equation (2.1). P =q·p 2.1.1 (2.1) Constant Flow Constant flow systems are the most commonly used systems in mobile applications today. It uses a pump with fixed displacement and an open centre valve. The system design is therefore fairly simple. Figure 2.1: Constant flow power figure 11 12 Basic Theory To obtain high energy efficiency in a constant flow system all of the pump flow needs to be used. In mobile applications this is often not the case. The unused flow will be throttled directly to the reservoir through the open centre valve from the current pressure level. Depending on the application and point of operation big energy losses might occur, see figure 2.1. A drawback with the constant flow system is that it is sensitive to actuator interference. It means that the speed of the lightest load will be affected by the heaviest load [1]. 2.1.2 Constant Pressure Constant pressure systems utilize a variable pump and a pressure regulator or a fixed pump and a relief valve to maintain a constant system pressure. If the actuators operate at the same pressure level as the pump the energy efficiency will be high. Otherwise big energy losses will occur, see figure 2.2. Unlike the constant flow system, the constant pressure system is not sensitive to actuator interference. This implies as long as the pump can supply the system with enough oil. If that is not the case the pump is saturated and the heaviest load will decrease in speed or even stop [1]. Figure 2.2: Constant pressure power figure 2.1.3 Load Sensing In mobile applications both pressure and flow tends to vary a lot during operation. Load sensing systems are equipped with a variable pump and a load pressure feedback. That gives the opportunity to adapt both pressure and flow to what is currently needed by the actuators which gives high energy efficiency. The weaknesses that might occur in a load sensing system are oscillations and slow response. Both are due to the load pressure feedback controlling the pump pressure [6]. In a load sensing system the pump pressure is continuously adjusted to the highest load pressure plus a constant pressure margin, ∆pp , see figure 2.3. Some 2.2 Pressure Compensation 13 pressure is lost in the pipes and the valve also needs a certain pressure drop. ∆pp is set to overcome all these losses and it is a necessary energy loss to guarantee the system operability [1]. Figure 2.3: Load sensing power figure 2.2 Pressure Compensation The valves in load sensing systems are often equipped with pressure compensators. There are different kinds of pressure compensators but the principle is the same: To maintain a constant flow through the main spool independent of variations in load and pump pressure. 2.2.1 Common Pre Compensation In a common pre compensated load sensing valve the compensator is placed up stream of the main spool. It acts in the same way as a pressure reducing valve where the reduced pressure pr acts on one side of the compensator and the load pressure pl together with a spring on the other, see figure 2.4 [9]. If the pump pressure increases the compensator reduces its orifice area and vice versa resulting in a constant output pressure. The principle is the same for the load pressure, when it decreases the compensator will reduce its orifice area and vice versa. The spring force depends on the preload, which is constant, and according to Hook’s law also the position of the compensator. Since the contribution from the preload is much bigger, the compensator position can be neglected, see equation (2.2). Fs = F0 + kxc ≈ /F0 kxc / ≈ F0 (2.2) Equation (2.2) together with the force equilibrium for the compensator, equation (2.3), and the flow equation gives the flow across the main spool. 14 Basic Theory Figure 2.4: Common pre compensators [5] F0 + Ac1 pl = Ac1 pr ⇔ F0 = Ac1 (pr − pl ) qs = Cq As r 2 (pr − pl ) = Cq As ρ s 2 F0 ρ Ac1 (2.3) (2.4) According to equation (2.4) the flow across the main spool depends on the main spool restriction area, As . Equation (2.4) is valid as long as the pump can supply sufficient flow. In a saturated situation the pump pressure will drop resulting in the compensator with the heaviest load will open completely. That function will then loose speed or even stop. Functions operated simultaneously at lower pressure levels will move normally. 2.2.2 Pre Compensation with Anti Saturation This type of compensators has the same features as the common pre compensators but also an anti saturation function. This means that all actuators can be given the same flow priority independent of variations in load- and pump pressure. In compensators with anti saturation functions there is no spring keeping the pressure drop across the main spool constant. The spring force has been replaced by two pressure signals that constitute ∆pp according to figure 2.5 and equation (2.5). 2.2 Pressure Compensation 15 Figure 2.5: Pre compensators with anti saturation [5] ∆pp = pp − pl,max (2.5) Equation (2.5) together with the force equilibrium for the compensator, equation (2.6), and the flow equation gives the flow across the main spool. Ac1 pp + Ac2 pl = Ac1 pl,max + Ac2 pr ⇔ (pr − pl ) = qs = Cq As r 2 (pr − pl ) = Cq As ρ Ac1 (pp − pl,max ) Ac2 s 2 Ac1 ∆pp ρ Ac2 (2.6) (2.7) According to equation (2.7) the flow across the main spool depends on the main spool restriction area, As , and the pump pressure margin, ∆pp . When the pump can supply sufficient flow, ∆pp remains constant and the flow only depends on the main spool restriction area. In a saturated situation ∆pp will drop and according to equation (2.7) the flow across all main spools will decrease proportionally. This is the main difference comparing to common pre compensated valves where the heaviest function will decrease in speed or even stop. 16 2.2.3 Basic Theory Post Compensation The functionality of post compensation is the same as with pre compensation with anti saturation. Both will distribute the flow between all functions in proportion to demand in a saturated situation. The pressure reduced by the main orifice po acts on one side of the compensator and the maximum load pressure pl,max together with a spring on the other, see figure 2.6 and equation (2.8). The same assumption with the spring according to equation (2.2) is done. Figure 2.6: Post compensators [5] Ac1 po = Ac1 pl,max + F0 ⇔ F0 = Ac1 (po − pl,max ) (2.8) Equation (2.5) and (2.8) together with the flow equation confirm that the flow only depends on the main spool restriction area according to equation (2.9). s r F0 2 2 (pp − po ) = Cq As (∆pp − ) (2.9) qs = Cq As ρ ρ Ac1 In a saturated situation ∆pp will drop and according to equation (2.9) the flow across all main spools will decrease proportionally. 2.3 Displacement Controlled System 2.3 17 Displacement Controlled System A displacement controlled system and is a non conventional fluid power system using similar components as a load sensing system. The difference is that it uses a displacement controlled pump without feedback instead of a pressure controlled pump with feedback, which is the case in a load sensing system. This means that the operator controls both the pump and the valve with the joystick. A consequence is that the demanded flow must be known [5]. A displacement controlled system does not suffer from the same oscillation problems as a load sensing system because it utilizes an open control without a load pressure feedback. The open control also increases the response time of the pump. By controlling the displacement of the pump, it allows a reduction of ∆pp which means energy savings [6]. 2.3.1 Flow Mapping To be able to calculate the demanded flow it is necessary to know how much flow that can pass by the valve. There are several ways to find out but they all need knowledge of the flow capacity in the valve. When the flow is known, the displacement of the pump can be calculated and sent to the pump controller according to equation (2.10). The pump will then deliver the flow demanded from the operator. qp = εp Dp np ηvol,p 2.3.2 (2.10) Compensation The same compensators used in load sensing system can be used in a displacement controlled system to prevent load interference. Problems might occur when using common pre compensated valves. If more flow is delivered from the pump than can pass by the valve the extra flow will build pressure and the pump pressure will hit its maximum value which will result in high energy losses. Using a valve with post compensation or a pre compensated valve with anti saturation will eliminate these problems. The extra flow will then be shared proportional to the active actuators. 2.3.3 Energy Savings Load sensing systems have a fixed ∆pp to overcome the pressure losses in the system. ∆pp is set in order to guarantee the system operability under all possible situations. However, in some situations parts of ∆pp is throttled in the compensator resulting in energy losses. Using a displacement controlled system this problem is avoided because the system compensates for pressure losses between pump and valve itself. The compensator does not need to reduce the pressure and energy efficiency will be high, see figure 2.7. 18 Basic Theory Figure 2.7: Dispacement controlled system power figure 2.4 Flow Forces The velocity of the oil is constant when approaching the inlet orifice. When coming towards the outlet orifice the velocity is increased. Because the absolute pressure is constant, the static pressure will decrease. The force acting on the spool by the outlet orifice is therefore less than the force by the inlet orifice. The resulting force is called the flow force and it will always act in the closing direction. Figure 2.8: Flow forces acting on a spool [4] 2.4 Flow Forces 19 The flow force is calculated according to equation (2.11) [7]. Fs = |2Cq wxs (p1 − p2 )cos(δ)| + ρlq̇ (2.11) Flow forces are defined positive in closing direction, explaining the absolute value on the static part of the equation. δ in equation (2.11) is the angel of the oil when passing by the outlet orifice, see figure 2.8. This angel is often approximated to 69 ◦ for small openings of the spool. Flow forces can be a problem in valves because the position of the spool is affected. With special geometry of the spool and the housing, the influence of flow forces can be reduced. But there are some cases when flow forces are of benefit. For example, a valve can be pressure compensated by flow forces. 20 Basic Theory Chapter 3 Design of Simulation Models In order to develop the displacement controlled system more knowledge about the system characteristics is necessary. A way of getting such knowledge is to simulate the whole system. Behaviours that hardly can be noticed otherwise can be detected while simulating and adjustment can be made. AMESim is the chosen simulation software in this master thesis. The software is based on components representing real physical models and is therefore simple to use and the models easy to overview. The program comes with standard libraries containing among other things hydraulic components. In this chapter, all simulation models that is necessary to design load sensing systems as well as displacement controlled systems will be explained. Geometric properties are determined from cad drawings and area curves for the spool are calculated using Parker´s inhouse program Veber. Unknown parameters such as flow forces and dynamic properties are determined by lab measurements, see chapter 4. The simulation models are designed using the hydraulic component design library which provides detailed hydraulic components. A basic hydraulic library is also available with standard models but the dynamics is limited. That library can be used when dynamics have less influence and the static behaviour is of interest. Because the simulation models are made in a comparative point of view they should not be seen as an exact image of the real components but more as a tool to compare different system designs. 3.1 Pump A variable axial piston pump is modelled in AMESim to simulate Parker´s P1075 pump. The model is a more general pump and do not have the same components as a real P1075 but parameters are adjusted to strive for similar behaviour. P1075 can either be controlled by pressure or by displacement, therefore two versions of the pump controller are modelled in AMESim. 21 22 Design of Simulation Models P1075 uses an electric pump controller called idec. To control the pump idec uses two pressure sensors, one displacement sensor and one rotary speed sensor. The controller and the sensors can be seen in figure 3.1. Output from the controller is a current which is sent to a solenoid acting on the control valve. The solenoid acts against a spring located on opposite side of the control valve. The control valve is a 4 port 2 position valve which directs oil to the control pistons. When the controller request an increase of the pump displacement the valve is positioned according to figure 3.1. Pump pressure is then directed to the spring loaded control piston. The other control piston is connected to reservoir, resulting in an increase of pump displacement. In the other case when a decrease of displacement is requested, pump pressure is directed to both control pistons. Because the spring loaded piston has a smaller area the resulting force will decrease the pump displacement. The control pistons act on the swash plate which controls the flow. The stroke of the pump pistons is dependent on the swash plate angel. An increase of the angel means larger stroke for the pump pistons which means that more flow is delivered from the pump. Figure 3.1: P1 pump controller [5] 3.1 Pump 3.1.1 23 Pressure Control In the simulation model the load pressure is connected to the pump and converted to an electric signal, see figure 3.2. ∆pp is then added to the load pressure signal. The pump pressure is also converted to an electric signal. The signals are then compared and the result is sent to a pid controller. The gain of the controller is adjusted to give expected behaviour, see section 4.2.1. The signal output from the controller is sent to a solenoid where it is transformed to a force acting on the control valve. The spring in the control valve is modelled with a mechanical spring. The spring force at zero displacement is set to zero to avoid static error in the control loop. When an increase of the pump displacement is requested the controller will send a signal to the solenoid which will move the spool to the left. Volume 1 is then connected to pump pressure and volume 2 to the reservoir. Each of the volumes are connected to the control pistons. If the spool is moved to the right, pump pressure is connected to volume 1 and 2. This is done by adding an underlap to piston 1. Volume 1 and 3 are therefore always connected independent of the spool position. Volume 1 is connected to the spring loaded control piston and volume 2 to the other control piston. The velocity and force from the pistons are transformed to angular velocity and torque using the transformers. The constants connected to the transformers are the lever arm between the pistons and the swash plate. The transformers are connected to rotary nodes used to synchronize the motion between the two control pistons. Relations between the motions is set in order to make the pistons move the same distance but in opposite direction when the swash plates angel changes. A third piston receives the pump pressure and acts on the swash plate by the transformer. The purpose is to simulate how the pump pistons on the high pressure side acts on the swash plate. The swash plate is simulated using an inertia connected to the rotary node. The inertia is also connected to an end stop of rotary motion. This is used to define maximum angel of the swash plate. An angel sensor receives the angel of the swash plate and is multiplied with a gain to calculate the displacement of the pump. The displacement signal is sent to an ideal pump model. Instead of simulating pump pistons an ideal pump is used as a flow source. Pressure ripples caused by the pump pistons has not been taken under consideration because it will not add any dynamics and high frequency ripple will increase the simulation time. As a power source a diesel engine with a certain torque and speed capacity should be used. In the model however the engine is assumed to have enough power to always keep a given speed. Therefore the engine is modelled as a constant speed source connected to the pump. 3.1.2 Displacement Control Instead of using pressures in the control loop, pump displacement and requested displacement are used, see figure 3.3. Pump displacement is measured from the 24 Design of Simulation Models displacement sensor and compared with the requested displacement which is an input to the model and the result is sent to the controller. Since the control error is smaller the controller gain needs to be higher. The signal output is send to the solenoid in the same way as the pressure control mode. Figure 3.2: Simulation model of a pressure controlled pump 3.1 Pump Figure 3.3: Simulation model of a displacement controlled pump 25 26 3.2 Design of Simulation Models Valve The modelled valve is Parker´s L90LS, which is a load sensing and pressure compensated directional valve. It is constructed for many different applications such as cranes, construction machinery and forest machinery. The valve can be equipped with up to 12 sections. It is constructed for 320 bar system pressure and a flow of 90 l/min with pressure compensators in each section. In figure 3.4 a cross section of the valve is shown. The main spool is controlled by a pressure reducing cartridge valve. To obtain a constant pressure drop across the main spool, different types of pressure compensators might be used. In this section common pre compensators and pre compensators with anti saturation will be explained. L90LS can also be equipped with two port relief valves in each section and a ∆pp limiter. Figure 3.4: L90LS valve 3.2.1 Cartridge Valve The L90LS valve is controlled by a pressure reducing cartridge valve called PVC25. It is an electro hydraulic valve delivering a pilot pressure to the main spool. When the machine operator moves the lever a current is sent to a solenoid. The solenoid transforms the current into a force acting on one side of the cartridge. The cartridge valve is supplied with pressure from the pump circuit. Because of varying pressure levels in the pump circuit a pressure reducer is used to provide the cartridge with a constant pressure, usually 22 or 35 bar. By changing its restriction area the cartridge can control the downstream pressure, which acts 3.2 Valve 27 against the solenoid. There is also a small leakage in the valve to achieve stability. The downstream pressure acts as a pilot pressure on the main spool. But first it passes through a damping orifice between the cartridge valve and the main spool, see figure 3.5. Figure 3.5: Pressure reducer and cartridge valve Simulation Model The important thing when modelling the cartridge valve is that the dynamics of the main spool is correct. Neither the pressure reducer nor the cartridge itself adds much dynamics. Most of the dynamics depends on the damping orifice. Because of that the cartridge can be simplified. In the simulation model a signal source represents the lever position in percent, see figure 3.6. The signal is recalculated into a pilot pressure and the preload of the spring controlling the main spool is added in the function box. The signal is then divided depending on the level position being positive or negative. Finally the pilot pressure is damped in orifice 1. To achieve correct dynamics the diameter of orifice 1 can be adjusted, see section 4.1.3. 28 Design of Simulation Models Figure 3.6: Simulation model of the cartridge valve 3.2.2 Main Spool To control the main spool, the cartridge provides the valve with a pilot pressure, see section 3.2.1. It acts on either side of the spool and works against a spring package. This spring package is placed on the right side of the spool but acts in both directions. When no pilot pressure acts on the spool, the spring package will place the spool in neutral position. To be able to move the spool, the pilot pressure needs to overcome the preload of the spring. To avoid leakage the spool has a under lap before it opens. Only a movement of the main spool in one direction will be explained, in this case a movement which will result in a lifting motion. If the movement was in the opposite direction the only difference is that the flow will be directed to the other motor port resulting in a lowering motion. When the spool is moved the load pressure holes will be connected with motor port A. The pressure in that motor port will then represent the load pressure for its section in the valve. The load pressure is taken through a channel inside the spool to volume 4, see figure 3.7. From this volume the load pressure is connected to a compensator, see section 3.2.3 and 3.2.4, and to the pump, see section 3.1. The pump port is also connected to port A when the spool is moved. At first the flow will only pass through the control notches and when the spool has been moved some more the whole ring area will open. Figure 3.8 shows how the restriction area of the spool depends on the spool position from pump port to motor port. The spool design can be different depending on the application. For example, the restriction area for port A can be different compared to port B, which is the case here. From port A, the flow goes to the actuator, see section 3.3. When it returns to the valve, it comes to motor port B. This port is connected to the reservoir. The oil will be throttled across the spool to the reservoir. Figure 3.8 shows how the restriction area of the spool depends on the spool position from motor port to reservoir. 3.2 Valve 29 Figure 3.7: Main spool 1 1 P−A B−T 0.9 0.8 0.8 0.7 0.7 Area/max area Area/max area 0.9 0.6 0.5 0.4 0.6 0.5 0.4 0.3 0.3 0.2 0.2 0.1 0.1 0 0 0.2 0.4 0.6 0.8 Position/max position 1 P−B A−T 0 0 0.2 0.4 0.6 0.8 Position/max position Figure 3.8: Restriction area for the main spool 1 30 Design of Simulation Models A small control notch is milled in the spool, see figure 3.7. When the spool is in neutral position the control notch will connect volume 4 with the reservoir. This means that the load pressure will drop until it reaches the pressure in the reservoir. Because of the load pressure feedback, the pump pressure can also drop and remain at standby pressure. Simulation Model The pilot pressure is connected to volume 5 and acts on piston 3. The spring package is represented by one spring on each side of the main spool. When the spool is moved towards one of the springs it will be compressed while the other spring will not be affected. By setting the correct preload and stiffness on the springs, they will work in the same way as the spring package. When the spool is moved to the right motor port A will be connected to volume 6 via an orifice in piston 4. The pressure in motor port A is the load pressure and it will be connected with the compensator via volume 6. If the spool is moved some more the pump port is connected to motor port A and flow can pass by the restriction in piston 5. By converting the spool position into restriction area and hydraulic diameter using a look up table, piston 5 represents both the control notches and the ring area. The hydraulic diameter is a commonly used term when handling flow in noncircular tubes and channels. Because of the complex geometry of the spool the restriction area is assumed be circular. The hydraulic diameter is thus equal to the diameter of the assumed circular restriction. This will have almost no significance in the simulation model because the flow will be turbulent anyway. The flow will be sent from motor port A to the actuator and move the load. It will then return to motor port B, which is connected to piston 6 where the flow passes by the restriction to the reservoir. Piston 6 also uses a look up table to convert spool position into restriction area and hydraulic diameter. Volume 6 is also connected to the reservoir via a variable orifice, which represent the small control notch in figure 3.7. When the main spool is in neutral position the variable orifice will open and the load pressure will drop. If the main spool is moved from neutral position the variable orifice will be closed. The mass in the model represent the mass of the spool and the end stops. The end stops are set to represent the length of the stroke. The model also consists of a position sensor. Even if there is no such sensor in the real valve it might be useful to know the spool position while simulating. 3.2.3 Common Pre Compensator At the left end of the compensator acts the load pressure together with a spring. The load pressure is connected to volume 4, see section 3.2.2, and passes through a damping orifice before it reaches the compensator. The spring is available in different designs depending on the stiffness. Differences in the stiffness will result in different pressure drops across the main spool and thereby different flows, see equation (2.4). 3.2 Valve 31 Figure 3.9: Simulation model of the main spool 32 Design of Simulation Models When the main spool is in neutral position the load pressure is the same as the pressure in the reservoir, see section 3.2.2. The compensator will be in its left position which means that no flow can pass by the restriction. When the main spool is moved the compensator will sense the load pressure and move to the right. Flow is then allowed to pass by the restriction and the pressure after the restriction will act on the right side of the compensator via a channel inside the compensator, see figure 3.10. Figure 3.10: Pre compensator Because of the force balance for the compensator, the reduced pressure after the restriction will be equal to the load pressure plus the resulting spring pressure, see equation (2.3). The compensator will find an equilibrium position by changing its restriction area resulting in a pressure drop across the compensator. How the restriction area depends on the compensator position can be found in figure 3.11. If the pump suffers from saturation the pump pressure will drop. Because the compensator strives to maintain the reduced pressure it will open more. If the pump pressure drops below the load pressure the flow direction will be reversed and the load will drop. To prevent this there is a check valve function in the compensator. If the compensator is moved to its right end position the check valve will close it. The check valve affects the restriction area of the compensator according to figure 3.11. Area/max area 1.5 Check valve Restriction 1 0.5 0 0,5 0,6 0,7 0,8 Position/max position 0,9 1 Figure 3.11: Restriction area for a common pre compensator 3.2 Valve 33 Simulation Model The load pressure is represented by a pressure source. It passes by orifice 2 and acts together with a spring at piston 7. Volume 7 represents the volume between the orifice and the compensator. The spring parameters can easily be changed in the model if another spring is more adequate for the current application. The pump pressure is also represented by a pressure source. When the compensator moves to the right flow can pass by the restriction in piston 8. Here the compensator position is converted into restriction area and hydraulic diameter by using a look up table. The pressure after the restriction acts on piston 9 on the right end of the compensator. Volume 8 represents the volume between the spool and the sleeve. Because the channel in the compensator is fairly big no orifice is needed in the model. After the restriction the flow passes by the check valve restriction, represented by piston 10, where the position is converted into restriction area and hydraulic diameter. When the compensator is in control position the check valve restriction has no influence on the pressure. Volume 9 represents the volume between the compensator and the main spool. Similar to the main spool, the compensator has a mass with end stops and a position sensor. Figure 3.12: Simulation model of a pre compensator 3.2.4 Pre Compensator with Anti Saturation The external pressures acting on the compensator are the load pressure in the valve section and the maximum load pressure. The load pressure is connected to the compensator via a damping orifice. The compensator has two different areas exposed to the control pressures. The load pressure acts on the bigger one on the left end of the compensator. The maximum load pressure is connected to the compensator via a damping orifice. It acts on the right end on the smaller area. On the other end of the compensator acts the pump pressure via a damping orifice on the smaller area. The resulting pressure acting on the smaller area is the pump pressure margin, ∆pp . 34 Design of Simulation Models When the main spool is in neutral position the load pressure is the same as the pressure in the reservoir, see section 3.2.2. The compensator will be in its left position which means that no flow can pass by the restriction. When the main spool is moved the compensator will sense the load pressure and move to the right. Flow is then allowed to pass by the restriction and the pressure after the restriction will act on the bigger area on the right end of the compensator via a channel, see figure 3.13. Figure 3.13: Pre compensator with anti saturation Because of the force balance for the compensator, the reduced pressure after the restriction will be equal to the load pressure plus a factor of the pump pressure margin, see equation (2.6). The compensator will find an equilibrium position by changing its restriction area resulting in a pressure drop across the compensator. How the restriction area depends on the compensator position can be found in figure 3.14. 1 Restriction Area/max area 0.8 0.6 0.4 0.2 0 0 0,1 0,2 0,3 0,4 0,5 0,6 Position/max position 0,7 0,8 0,9 1 Figure 3.14: Restriction area for a pre compensator with anti saturation The factor of the pump pressure margin can be compared to the stiffness of the spring used in a common pre compensated valve. Both will determine the pressure drop and thus the flow across the main spool according to equation (2.4) and (2.7). If the pump pressure margin for some reason changes, it can be compared to a change in the spring stiffness. 3.2 Valve 35 Simulation Model The compensator has been modelled as one part, but actually it consists of three parts. The pressures acting on the left piston are the pump pressure and the load pressure. Since the pump pressure will be higher than the load pressure in almost every situation an assumption has been made: The left piston will always be in its left end position and thus not affect the force balance of the spool. The right piston on the other hand will affect the force balance of the spool. If the maximum load pressure is higher than the reduced pressure the right piston will push the spool to the left and in the opposite case pull the spool to the right. The force equilibrium for the right piston is shown in equation (3.1). pr Ac2 = pl,max Ac2 (3.1) When looking at the force equilibrium for the spool, pump pressure and load pressure will act to the left on the smaller respectively bigger area. On the right side the reduced pressure will act on the smaller and bigger area. The force equilibrium for the spool is shown in equation (3.2). pl Ac1 + pp Ac2 = pr (Ac1 + Ac2 ) (3.2) When taking the contribution from the right piston on the spool under consideration, equation (3.1) can be put into equation (3.2) resulting in the force equilibrium for the compensator, see equation (3.3). pl Ac1 + pp Ac2 = pr Ac1 + pl,max Ac2 (3.3) The load pressure is represented by a pressure source. It passes by orifice 3 and acts at piston 11, which represents the bigger area exposed to the control pressures. Volume 10 represents the volume between the orifice and the compensator. The maximum load pressure is also represented by a pressure source. It passes by orifice 4 and acts at piston 12, which represents the smaller area. Volume 11 represents the volume inside the sleeve. The pump pressure is represented by a pressure source. It passes by orifice 5 and acts at piston 13, which represents the smaller area. Volume 12 represents the volume that arises between the spool and the left piston. When the compensator moves to the right flow can pass by the restriction in piston 14. The compensator position is converted into restriction area and hydraulic diameter by using a look up table. The pressure after the restriction passes by orifice 6 and acts on piston 15, which represents the bigger area. Volume 13 represents the volume between the spool and the sleeve and volume 14 represents the volume between the compensator and the main spool. The compensator also has a mass with end stops and a position sensor. Orifice 6 is modelled as one restriction with 1.5 mm in diameter. This is a simplification because there are actually four radial holes with 1 mm in diameter each. Those holes are then connected to a channel inside the spool with 1.5 mm in diameter. The assumption has been made that the channel is limiting and the diameter of orifice 6 is set to the diameter of the channel. 36 Design of Simulation Models Figure 3.15: Simulation model of a pre compensator with anti saturation 3.2.5 ∆pp Limiter The ∆pp limiter is a pilot controlled pressure relief valve used to limit the difference between pump pressure and maximum load pressure, ∆pp . The cracking pressure for the valve is the maximum load pressure plus a spring preload. By adjusting the preload of the spring ∆pp can be limited. Simulation Model Pump pressure acts on the poppet. On the opposite side acts the maximum load pressure together with a spring on piston 16. As long as the pump pressure is less than the maximum load pressure plus the spring preload the valve will be closed. If the pump pressure is higher, the valve will open and pump pressure will be throttled to the reservoir resulting in a limitation of ∆pp . Figure 3.16: Simulation model of a ∆pp limiter 3.3 Actuator 3.3 37 Actuator The actuators in the system are cylinders. The cylinder is connected with two hoses from the valve and can therefore be controlled in both directions. When oil is directed to the piston side of the cylinder the stroke increases. Since the rod is located on the opposite side less flow will be sent back to the valve. The cylinder in the model is not designed to represent a specific cylinder. Instead it can be seen as a general cylinder. A mass model is used to define the mass and the stroke of the piston. An appropriate value of the viscous friction has been estimated in order to eliminate oscillations and speed up the simulation. A signal source is transformed into a force connected to the mass. The signal can be positive or negative resulting in a force that pulls or pushes the piston. The cylinder is simulated with a simple model from the standard hydraulic library. Figure 3.17: Simulation model of an actuator 3.4 Load Sensing Systems In this section, the simulation models explained earlier in this chapter will be utilized to build a load sensing system. To get a better overview of the system, the super component function in AMESim is used. This means that all components are hidden in an icon representing the simulation model. To get a better understanding of the system, it will be explained what happens when the operator tilts its lever. When the signal source in the lever is activated an electric signal is transformed to a pilot pressure acting on the main spool. The main spool will then move and the load pressure will be in contact with the compensator and the shuttle valve. If no other pressure acts on the shuttle valve it will send the load pressure to the pump via the load pressure feedback pipe. How to achieve a correct pressure build up in the pipe can be seen in section 4.2.2 In the pump the controller makes sure that the pump pressure margin is obtained by increasing the displacement. Flow is now delivered to the valve via the pipe connecting the pump and the valve. To achieve correct pressure losses in the pipe the diameter and the length are adjusted, see section 4.2.3. By changing its restriction area, the compensator reduces the pressure before the oil comes to the main spool. There is also a pressure drop across the main spool before the oil reaches the actuator. In the simulation model the actuators are of the same size in order to simplify the model. When the actuator is moving, oil from the piston rod side will be throttled across the main spool and finally reach the reservoir. 38 Design of Simulation Models The maximal load pressure will also affect the cracking pressure for the ∆pp limiter, referred to as the pls valve. The system also consists of a PLS limiter, which limits the load pressure and therefore also the load pressure feedback connected to the pump. If the system is equipped with a pre compensating valve with anti saturation, the maximal load pressure will be connected to the compensator as well. Figure 3.18: A load sensing system with common pre compensators 3.4 Load Sensing Systems 39 Figure 3.19: A load sensing system with pre compensators with anti saturation 40 3.5 Design of Simulation Models Displacement Controlled Systems A model of a displacement controlled system equipped with common pre compensators can be seen in figure 3.20. The only difference compared to the model of a load sensing system with common pre compensators, see figure 3.18, is that the load pressure feedback is removed and the displacement of the pump is controlled directly by the operator via a flow map. If the system is equipped with a pre compensating valve with anti saturation, the maximal load pressure will be connected to the compensator as well, see figure 3.21 Figure 3.20: A displacement controlled system with common pre compensators 3.5 Displacement Controlled Systems 41 Figure 3.21: A displacement controlled system with flow sharing capabilities 42 Design of Simulation Models Chapter 4 Validation of Simulation Models To be able to validate simulation models and determine unknown parameters, laboratory measurements are necessary. In the laboratory, flows, pressures and positions can be measured by sensors during testing. Parameters in the simulation models can then be adjusted to strive for the same result as in the laboratory test. In this chapter, a laboratory platform as well as a test rig will be utilized to validate the simulation models. The models will be validated separately at first and then together in a familiar system, in this case a load sensing system on the test rig. 4.1 Laboratory Platform The L90LS valve was set up in a laboratory platform. A variable orifice representing the load is connected to the motor port. By adjusting the area of the orifice the pressure in the motor port can be set. The orifice is connected to either motor port A or B depending on which test being made. The oil is directed directly to the reservoir after the orifice and not through the valve. This is because the motor port connected to the load should not be affected by the other motor port. To control the main spool a PVC25 is connected to a current source, see figure 4.1. During the tests the pump pressure is set to a constant value of 250 bar. An external pilot pressure representing the maximum load pressure is connected to the load sensing port lspb and the connection between lspb and t2b/t3b is plugged, see figure 4.2. The pilot pressure is set to a constant value of 230 bar. The difference between the pump pressure and the maximum load pressure, ∆pp , is therefore 20 bar during the tests. The parameters measured during the laboratory test are shown in table 4.1. 43 44 Validation of Simulation Models Table 4.1: Measured parameters in the laboratory tests Number 1 2 3 4 5 6 7 8 Quantity Position of the main spool Current to the PVC25 Pilot pressure on the spool, A side Pilot pressure on the spool, B side Pump pressure Motor port pressure Reservoir pressure Flow Unit [mm] [mA] [bar] [bar] [bar] [bar] [bar] [l/min] Figure 4.1: Setup during laboratory tests Figure 4.2: Plugged connection between lspb and t2b/t3b 4.1 Laboratory Platform 45 ∆p/q Test 4.1.1 100 100 90 90 80 80 70 70 60 60 Flow [l/min] Flow [l/min] The spool position is set to an initial position and the electrical current to the PVC25 is constant during the test. The motor port pressure is changed from 250 bar to 50 bar and back to 250 bar. The pressure difference between pump pressure and load pressure, ∆p, is hence changed from 0 to 200 bar. This is made for different initial positions of the spool with common pre compensators and pre compensators with anti saturation. During the ∆p/q test, the pressure drop across the valve will change but since the valve is pressure compensated the flow will remain constant. According to the left plot in figure 4.3 and 4.4, both compensators acts as they are supposed to. The flow remains reasonably constant when ∆p is increased. The same test can be simulated and the results agrees reasonably well with the measurements, see the right plot in figure 4.3 and 4.4. 50 40 50 40 30 30 20 20 10 10 0 0 50 100 150 Pump pressure margin [Bar] 200 0 0 50 100 150 Pump pressure margin [Bar] 200 Figure 4.3: ∆p/q test using common pre compensators The same test was also done with the load connected to motor port B instead of motor port A. Since the spool is almost symmetric the result is the same. 4.1.2 Flow Forces A ∆p/q test is also made without pressure compensators because the L90LS valve can be used without them. In order to prevent the flow from going in the wrong direction a check valve is used instead of a compensator. The pressure difference between the pump and the motor port will then occur across the main spool. Flow forces will act only on the meter in orifice since the oil is directed directly to the reservoir after the load. The position of the spool is measured during changes in the pressure drop across the main spool. The influence of flow forces can be seen in the left plot in Validation of Simulation Models 120 120 100 100 80 80 Flow [l/min] Flow [l/min] 46 60 60 40 40 20 20 0 0 50 100 150 Pump pressure margin [Bar] 0 0 200 50 100 150 Pump pressure margin [Bar] 200 Figure 4.4: ∆p/q test using pre compensators with anti saturation 6 6 5.5 5.5 5 5 Spool position [mm] Spool position [mm] figure 4.5. In the simulation model the Kjet factor in piston 5 and 6, see figure 3.9, can be adjusted to give the right behaviour, see the right plot in figure 4.5 and figure 4.6. 4.5 4 3.5 3 2.5 2 0 4.5 4 3.5 3 2.5 50 100 150 Pump pressure margin [Bar] 200 2 0 50 100 150 Pump pressure margin [Bar] 200 Figure 4.5: The influence of flow forces On the meter out orifice the influence of flow forces is reduced with special geometry of the spool. Therefore flow forces on the meter out orifice are set to zero [8]. 4.2 Test Rig 47 6 Spool position [mm] 5.5 5 4.5 4 3.5 3 2.5 2 0 20 40 60 80 100 120 Pump pressure margin [Bar] 140 160 180 200 Figure 4.6: The affects of flow forces in laboratory and simulation 4.1.3 Step Response The main spool position is set to an initial position by changing the current to the PVC25. The current is then switched off resulting in no pilot pressure and the main spool in neutral position. When the current is switched on again a step will be made in the current and thus in the main spool position, see figure 4.7. By adjusting the orifice in the simulation model of the PVC25 the similar behaviour can be seen in the simulations. Since the orifice is enough to get the expected dynamics the cartridge valve and the pressure reducer can be neglected, see section 3.2.1. 6 6 Main spool position in simulation Main spool position in laboratory 5 5 4 4 Position [mm] Position [mm] Main spool position in laboratory 3 3 2 2 1 1 0 0 0.5 1 Time [s] 1.5 2 0 0 0.5 1 Time [s] 1.5 2 Figure 4.7: Main spool step response 4.2 Test Rig A compact wheel loader, Zettelmeyer 802 Si, is used as a test rig, see figure 4.8. The machine is equipped with a P1 pump and a L90LS valve. The pump can be both pressure and displacement controlled allowing a load sensing system and a 48 Validation of Simulation Models displacement controlled system to be tested on the same machine. The actuators are cylinders controlling the lift and tilt functions. The valve is equipped with both common pre compensators and pre compensators with anti saturation for each function. Parker´s iqan system controls the hydraulic and consists of an ecu and several i/o units. Sensors are connected to the system and iqan is used to collect data. Figure 4.8: Zettelmeyer 802 Si [5] The parameters measured during testing are shown in table 4.2. Table 4.2: Measured parameters in the test rig Quantity Pump pressure Pump pressure Load pressure Motor port pressure Motor port pressure Motor port pressure Motor port pressure Position Position Pump rotational speed Pump cam position Command signals Location Pump Valve Valve Lift A-side Lift B-side Tilt A-side Tilt B-side Lift cylinder Tilt cylinder Engine IQAN IQAN Unit [bar] [bar] [bar] [bar] [bar] [bar] [bar] [cm] [cm] [rev/min] [%] [%] 4.2 Test Rig 4.2.1 49 Pump The test rig is used to validate the pump. A step is done in the lever and the pump pressure is measured. Since the measurement is done on a mobile application the pressure will oscillate with a low frequency because the machine swings when a step is done. The pump will also cause pressure ripples. To keep the pump model simple those phenomenon are not considered in the simulation. The most important thing is the on stroke time, see figure 4.9. The gain of the pump controller is adjusted for pressure mode and displacement mode. Since the control error is smaller in displacement mode, a higher gain is needed compared to load sensing mode. The gain together with the orifice area for piston 2 in the pump control valve, see figure 3.2, is adjusted to give the right on stroke time. 120 120 Pump pressure in simulation Pump pressure in test rig 100 100 80 80 Pressure [Bar] Pressure [Bar] Pump pressure in test rig 60 40 20 0 0.8 60 40 20 0.9 1 1.1 Time [s] 1.2 1.3 1.4 0 0.8 0.9 1 1.1 Time [s] 1.2 1.3 1.4 Figure 4.9: P1 pump validation 4.2.2 Load Pressure Feedback When modelling the load pressure feedback pipe, friction, compressibility and wave dynamics could be taken into consideration. The friction is however neglected because there is almost no flow in the pipe. Wave dynamics are only of interest if the time taken by a wave to travel along the pipe is longer than the sampling rate, see equation (4.1). twave = r ρ L =L ≈ 5ms c βe (4.1) Since the communication interval with iqan is 10 ms there is no need to take wave dynamics into account. The pipe can hence be considered as a closed volume. The time it takes for the pressure to be built up in a closed volume depends on the bulk modulus and the volume, see equation (4.2). dp βe = Σqin dt V (4.2) 50 Validation of Simulation Models The pressure build up can be validated by measurements on the test rig. If a step is done in the command signal pressure will be built up in the load pressure feedback. By plotting the load pressure as a function of time the pressure build up can be seen in figure 4.10. In the simulation model the compressibility of the fluid and expansion of the pipe wall are taken into account by using an effective bulk modulus. This is calculated based on the wall thickness and Young’s modulus for the wall material. The length and diameter gives the volume of the pipe. A comparison between the model and the measurement can be seen in figure 4.10. 100 100 Load pressure in simulation Load pressure in test rig Load pressure in test rig 80 Pressure [Bar] Pressure [Bar] 80 60 40 20 0 1 60 40 20 1.1 1.2 Time [s] 1.3 1.4 0 1 1.1 1.2 Time [s] 1.3 1.4 Figure 4.10: Pressure build up in the load pressure feedback pipe 4.2.3 Pressure Losses When modelling the pipe between the pump and the valve pressure losses must be kept in mind. Pressure losses arise due to friction between the fluid and the wall of the pipe and the friction in the fluid. Pressure losses due to friction can be calculated according to equation (4.3). Also one time losses and losses due to a disturbance source will arise but they are not considered in this master thesis. ∆pf = λ l ρv 2 d 2 (4.3) The test rig can be used to validate pressure losses. The difference between the pressure at the pump and at the valve are pressure losses, ∆pf . By increasing the flow, ∆pf as a function of the flow is obtained, see figure 4.11. In the simulation model, the length and diameter of the pipe can be changed to achieve appropriate pressure losses, see figure 4.11. The friction factor λ is calculated by AMESim and the density is considered constant. Pressure losses also occur in the pipes connecting the valve and the actuators. This is however not considered in the simulation model because the pressure in the motor ports is measured next to the valve on the test rig. To compensate for this simplification the force acting on the cylinder might be made a little bigger in the model. 4.3 Load Sensing Systems 51 150 10 Pressure [Bar] Flow [l/min] Flow in test rig 100 50 0 2 3 4 Time [s] 5 3 4 Time [s] 5 6 10 Pressure [Bar] Flow in simulation Flow [l/min] 5 0 2 6 150 100 50 0 2 Pressure losses in test rig 3 4 Time [s] 5 6 Pressure losses in simulation 5 0 2 3 4 Time [s] 5 6 Figure 4.11: Pressure losses in the pipe connecting the pump and the valve The compressibility in the pump- and actuator pipe is difficult to validate but appropriate values has been estimated. Wave dynamics has not been taken into account for the same reason as in section 4.2.2. 4.3 Load Sensing Systems To make sure that the simulation models of the load sensing systems act as they are supposed to, two different tests are made in the test rig and compared with the simulation models. The same tests are also made in the test rig using a displacement controlled system, see chapter 6. Since the simulation models are used to evaluate the system characteristics it cannot be compared exactly to the measurements done on the test rig. The important thing is that the behaviour is correct. For example, in the test rig the cylinders have different diameters resulting in different flow demand for the same velocity. In the simulation models the cylinders are identical to simplify the comparison between the two functions. 4.3.1 Pump Saturation When the pump is saturated different system behaviour can be expected depending on what compensator being used. If the valve is equipped with common pre compensators actuator interference will occur, see section 2.2.1. When using pre compensators with anti saturation that problem can be avoided, see section 2.2.2. A way to test this on the test rig is to increase the lever position to both functions until the pump cannot supply sufficient flow. By continuing to increase the command signal the behaviour in a saturated situation is shown. The heaviest load is represented by the lift function and the lightest load by the tilt function. The first test is made with common pre compensators. 52 Validation of Simulation Models 120 0.4 Lift actuator position Tilt actuator position Lift and tilt command 100 0.3 Position [m] Lever [%] 80 60 0.2 40 0.1 20 0 0 1 2 3 Time [s] 4 5 0 0 6 1 2 3 Time [s] 4 5 6 Figure 4.12: A saturated situation with common pre compensators in the test rig As seen in figure 4.12, both functions will move with the same velocity until maximal flow from the pump is delivered. The velocity of the tilt will then continue to increase while the lift will loose speed. Eventually all pump flow will be delivered to the tilt and the lift will stop completely. When the same test is made in the simulation model the same result is achieved according to figure 4.13. The interesting part is however to analyse how the compensators work to attain this behaviour. When the pump cannot supply sufficient flow ∆pp will decrease. To prevent the reduced pressure to decrease, the compensator at the lift function will increase its restriction area according to figure 4.13. When the compensator no longer can maintain a constant pressure drop across the main spool the flow and thus the velocity will decrease. If the reduced pressure drops below the load pressure plus the resulting spring pressure check valve position will be reached and the function will stop according to section 3.2.3. 100 0.4 Tilt actuator position Lift actuator position Position [m] Lever [%] Lift and tilt command 50 0 0 1 2 3 4 0.3 0.2 0.1 0 0 5 1 2 Time [s] 4 5 15 Tilt compensator area Lift compensator area 1 Pressure [Bar] Area/max area 1.5 0.5 0 0 3 Time [s] 1 2 3 Time [s] 4 5 Pressure drop across lift main spool 10 5 0 0 1 2 3 4 5 Time [s] Figure 4.13: A saturated situation with common pre compensators in simulation 4.3 Load Sensing Systems 53 This is not a problem for the tilt function because the pressure drop across the compensator is higher. Its restriction area will also increase but the reduced pressure can be kept constant according to figure 4.13. The same test is made using pre compensators with anti saturation. According to figure 4.14 the same velocity is obtained, also when the pump suffers from saturation. If the test is made in the simulation model the expected result is obtained according to figure 4.14. 0.4 Tilt actuator position in test rig Lift actuator position in test rig 0.4 Position [m] Position [m] 0.6 0.2 0 0 1 2 3 4 Tilt actuator position in simulation Lift actuator position in simulation 0.2 0 0 5 1 2 Time [s] 4 5 40 Tilt compensator restriction area Lift compensator restriction area 1 Pressure [Bar] Area/max area 1.5 0.5 0 0 3 TIme [s] 1 2 3 Time [s] 4 5 Pump pressure margin 20 0 0 1 2 3 4 5 Time [s] Figure 4.14: A saturated situation with pre compensators with anti saturation As seen in figure 4.14 the compensator at the lightest section will hold its restriction area almost constant when the pump is saturated. The other compensator however will increase its restriction area in order to maintain the same pressure drop across both main spools. Hence, the same velocity for both functions is obtained. 4.3.2 Step Response A step is made to validate the simulation model but also to compare the performance between a load sensing system and a displacement controlled system. This comparison is made in section 6.3. The test is made with two different functions. The lift function represents the heaviest load and the tilt function the lightest. A step is made in the command signal for the tilt and two seconds later a step is made with the lift. Finally the command signal to the lift is shut off, see figure 4.15. According to figure 4.15 the velocity of the tilt is barely affected despite of the pump pressure being increased. When making the same test in the simulation model the compensator to the tilt can be studied to find out why the velocity remains constant. As seen in figure 4.16 the behaviour of the pump pressure and the position of the actuators correspond to the measurements on the test rig. When the step in the tilt is made the compensator finds its equilibrium position by changing its restriction area. A constant pressure drop across the main spool 54 Validation of Simulation Models 100 150 Lift command Tilt command Pump pressure Pressure [Bar] Lever [%] 80 60 40 20 100 50 0 0 1 2 3 TIme [s] 4 5 0 0 6 1 2 3 Time [s] 4 5 6 Position [m] 0.8 Lift actuator position Tilt actuator position 0.6 0.4 0.2 0 0 1 2 3 Time [s] 4 5 6 Figure 4.15: Step response made in the test rig and thus a constant flow is then obtained. When the step in the lift is made the pump pressure increases because of the higher load. The compensator will then find a new equilibrium position by decrease its restriction area. It results in a higher pressure drop across the compensator but still a constant reduced pressure. Hence the flow remains constant. When the lift is shut off the pump pressure will decrease and the compensator will return to its previous position, see figure 4.16. 50 0 0 1 2 3 4 Pump pressure 100 50 0 0 5 Tilt actuator position Lift actuator position 0.3 0.2 0.1 0 0 150 Time [s] 0.4 Position [m] Pressure [Bar] Tilt command Lift command Position [mm] Lever [%] 100 1 2 3 Time [s] 4 5 1 2 3 4 5 Time [s] 6 Tilt compensator position 4 2 0 0 1 2 3 Time [s] Figure 4.16: Step response made in the simulation model 4 5 Chapter 5 Design of Displacement Controlled Systems The main difference when controlling the displacement of the pump instead of the pressure is that the load pressure feedback is removed. Instead the pump receives a requested displacement from the operator. This principle might imply higher energy efficiency, faster response and less oscillations. Figure 5.1: Displacement controlled system [5] In this chapter, two different types of displacement controlled systems will be studied. The differences between these systems are what compensator being used. 55 56 Design of Displacement Controlled Systems At first a displacement controlled system equipped with common pre compensators will be discussed. 5.1 Flow Mapping In a displacement controlled system the flow delivered from the pump need to be matched against the flow received by the valve. In this section it will be explained what factors that will affect the flow calculation across the valve and from the pump. 5.1.1 Valve Control When the operator tilts the lever a current is sent to the cartridge valve. The cartridge valve will move the main spool with a pilot pressure proportional to the received current. Since the main spool acts against a spring the pilot pressure is proportional to the main spool position when the preload of the spring is overcome. A position corresponds to a certain restriction area of the main spool, see figure 3.8. The flow across the main spool will depend on the main spool restriction area and the pressure drop according to equation (5.1). r p 2 ∆ps ∝ As ∆ps qs = Cq As (5.1) ρ The pressure drop across the main spool will be equal to the resulting spring pressure of the compensator. The spring used in this master thesis will give a pressure drop between 4.5 and 6.5 bar within the compensators control position. Control position of a common pre compensator means that the compensator is able to maintain a pressure drop between the above mentioned values across the main spool independent of variations in pump- and load pressure. If the pressure drop goes below 4.5 bar check valve mode is reached and the restriction area will decrease, see figure 3.11. There are other springs available resulting in different pressure drops across the main spool but they are not considered in this master thesis. A certain lever position will result in a certain restriction area for the main spool. But since the compensator can hold a pressure drop between 4.5 and 6.5 bar different flows are possible for the same lever position. In figure 5.2 the flow is plotted against the lever position. The flow for two different pressure drops is plotted, one for 4.5 bar and the other for 6.5 bar. This creates a flow field which the compensator can hold within its control position. 5.1 Flow Mapping 57 180 160 4.5 bar pressure drop 6.5 bar pressure drop 140 Flow [l/min] 120 100 80 60 40 20 0 0 10 20 30 40 50 60 Command signal [%] 70 80 90 100 Figure 5.2: Flow field when using common pre compensators 5.1.2 Pump Control In order to deliver a flow from the pump corresponding to the flow field the lever position needs to be transformed to a flow. This could be done by measuring the command signals and use known relationships between command signals, current, pilot pressure, spool position and spool area. A pressure drop within the control position of the compensator could then be assumed and the flow calculated according to equation (5.1). But there is uncertainty in each step between command signal and flow. The tolerance of the components and factors like flow forces might affect the calculations. Adding up these uncertainties will make the calculations of the flow too unsure to use. Another method is required. A load sensing system with common pre compensators can be used instead to calculate a flow map. A ramp can be made in the command signal and the flow measured. The flow can then be plotted as function of the command signal. Since the load pressure feedback is used to control the system pressure and the pump can supply sufficient flow, the compensator will be in its control position and hence the flow will be inside the flow field. To calculate the required displacement of the pump the flow map is used to transform a lever position into a flow. The flow demand from each section is summed up and sent to the pump controller. Here the maximal possible flow is calculated from the rotational speed of the pump and a displacement is ordered according to the requested flow. At the same time the lever position is sent to the valve resulting in a proportional manoeuvring of the main spool. When measuring the shaft speed of the pump there might be some inaccuracy in the test rig because of the analogue communication between the ecu and the pump controller. Since the volumetric efficiency of the pump depends on the current system pressure it might also be a source of problem. Because of this the pump will not deliver the exact amount of flow demanded by the operator. 58 5.2 Design of Displacement Controlled Systems System Characteristics The characteristics of a displacement controlled system are to some extent different compared to a load sensing system. In this section differences concerning response behaviour, dynamic stability and system pressure will be discussed. 5.2.1 Response Behaviour In a load sensing system a sequence of operations must take place between command signal and pump respond. At first the joystick generates a pilot pressure which displaces the main spool. The highest load pressure can then travel through the load pressure feedback and the pump changes its displacement and generates flow. When controlling the displacement of the pump a command signal will generate a pilot pressure and at the same time a requested displacement will be sent to the pump. Therefore the pump and the valve should react simultaneously on the command signal [6] [2]. The pump controller used in the test rig is not optimal for controlling the displacement. Because of that, there is no focus on the response behaviour in this master thesis. As shown in section 6.3 the response in a load sensing system is equal to the response in a displacement controlled system with the current pump controller. 5.2.2 Dynamic Stability Pressure controlled pumps operate in a pressure closed loop control mode where the highest load pressure can change significantly. Factors such as oil temperature, natural frequencies and damping levels might affect this loop. Therefore a fixed setting of the control parameters must be a compromise across all operating conditions. Unfortunately some operating conditions might exceed the stability limit resulting in an increase of the hydraulics tendency to oscillate [6] [2]. When the pump is displacement controlled it operates in an open control since the requested displacement is set by the operator. Problems related to the load pressure feedback are therefore terminated and less oscillations can be expected. However, this is considered outside of this master thesis scope but might be of interest in future investigations. 5.2.3 System Pressure In a load sensing system the pump controller will adjust the pump pressure in order to maintain the pump pressure margin, ∆pp . To control the pressure the pump changes its displacement resulting in a flow. The flow will hence be changed automatically in order to maintain ∆pp and the pump pressure will be the highest load pressure plus ∆pp . When the pump is displacement controlled it will deliver the flow demanded from the operator. On its way to the actuators the oil will pass several restrictions creating pressure losses. Also friction in the pipes will result in pressure losses, 5.3 Incorrect Flow Delivery 59 see section 4.2.3. Hence the pump pressure will be automatically adjusted to the highest load pressure plus the pressure losses in order to deliver the demanded flow to the actuators. The similar behaviour can be seen in a constant flow system when no flow is throttled through the open centre valve. The pump pressure margin used in load sensing systems is set to a fixed level in order to transport oil to the actuators across all flow resistances and under the most unfavourable conditions, such as cold oil or maximal flow rate. However during other conditions ∆pp is too high and pressure is throttled across the compensators resulting in a waste of energy. Because the system pressure is automatically adjusted when controlling the displacement of the pump, an optimal system pressure is always achieved. Both flow and pressure is thus adapted to what is needed by the actuators in every possible situation and the energy efficiency will therefore be very good, see figure 5.3. Observe that this implies as long as the pump do not deliver too much flow, see section 5.3.2. Figure 5.3: Load sensing and displacement controlled power figure 5.3 Incorrect Flow Delivery When calculating the flow map with measurements from the load sensing system the position of the compensator is unknown. The exact pressure drop across the main spool and thus the position in the flow field is therefore also unknown. This means that the flow map could be close to the boundary of the flow field. It is interesting to see what happens if the flow delivered from the pump is outside the flow field. The simulation model of a displacement controlled system equipped with common pre compensators, see figure 3.20, can be used to simulate if not enough or too much flow is delivered. 60 Design of Displacement Controlled Systems 5.3.1 Not Enough Flow is Delivered Two different loads are used in the simulation, the heaviest represent by the lift function and the lightest by the tilt function. The same constant lever position is used for both functions. The demanded flow is then decreased from a value inside the flow field. 1.5 Tilt actuator position Lift actuator position 0.4 Area/max area Position [m] 0.5 0.3 0.2 0.1 0 71 70 69 68 67 66 Flow [l/min] 65 64 0.5 1 2 3 4 5 Time [s] 30 Pressure drop across lift main spool Pressure [Bar] Pressure [Bar] 1 0 0 63 10 5 0 0 Lift compensator area 1 2 3 Time [s] 4 5 Pump pressure margin 20 10 0 0 1 2 3 4 5 Time [s] Figure 5.4: System characteristics when not enough flow is delivered As seen in figure 5.4, the velocity will be the same for the functions when the pump delivers flow according to the flow field. But as the demanded flow decreases ∆pp will decrease. The compensator with the heaviest load will therefore increase its restriction area to maintain a constant pressure drop across the main spool. As ∆pp decreases the compensator is unable to hold a pressure drop within its control area. The function with the heaviest load will therefore decrease in speed since the pressure drop across the main spool is decreased. The same behaviour can be seen in a load sensing system with common pre compensators when the pump is saturated, see section 4.3.1. The consequence if the pump delivers insufficient flow is hence actuator interference. 5.3 Incorrect Flow Delivery 5.3.2 61 Too Much Flow is Delivered It is also interesting to see what happens if the delivered flow is outside the flow field and too much flow is delivered from the pump. To test this scenario the same simulation is made as in section 5.3.1, but the demanded flow is now increased from a value inside the flow field. Only one actuator is needed in the simulation to show what happens. 0.4 300 Pressure [Bar] Position [m] Lift actuator position 0.3 0.2 0.1 0 72 73 74 75 76 Flow [l/min] 77 78 Pump pressure 200 100 0 0 79 3 4 5 15 Lift compensator area Pressure [Bar] Area/max area 2 Time [s] 0.8 0.6 0.4 0.2 0 0 1 1 2 3 4 5 Pressure drop across lift main spool 10 5 0 0 Time [s] 1 2 3 4 5 Time [s] Figure 5.5: System characteristics when too much flow is demanded As seen in figure 5.5, the velocity of the actuator will remain constant independent of the flow increase. Since more flow is delivered from the pump than the actuator receives pressure will be built in the pipe connecting the pump and the valve according to equation (5.2). dp βe = Σ(qin − qout ) dt V (5.2) When the pressure is built up the compensator will reduce its restriction area in order to maintain a constant pressure drop across the main spool. The pressure in the pipe connecting the pump and the valve will increase until it exceeds the cracking pressure for the ∆pp limiter. The flow will then be throttled to the reservoir in order to maintain a maximum system pressure. In figure 5.5 the cracking pressure for the ∆pp limiter is set very high in order to see when the pressure increases. If a lower cracking pressure is set, the ∆pp limiter will throttle the flow to the reservoir resulting in energy losses. Demanding to much flow will result in energy losses. Since the pump pressure increases and the load pressure remains constant unnecessary pressure losses will occur across the compensator. Also the ∆pp limiter will contribute to the energy losses. The extra flow delivered from the pump, which not passes through the valve, will be throttled to the reservoir resulting in high energy losses. 62 Design of Displacement Controlled Systems 5.4 Displacement Controlled System with Flow Sharing Capabilities As explained in section 5.3 problems occur when controlling the displacement of the pump and using a common pre compensating valve. Too many factors are unknown and the consequence if an incorrect flow is delivered from the pump is either energy losses or actuator interference. This is not acceptable and a better solution is a necessity. The flow across the main spool is dependent of the restriction area and the pressure drop according to equation (5.1). If the area is kept constant by the operator and the flow varies because of for example inaccuracy in the pump control the pressure drop also needs to vary. With common pre compensators the pressure drop is only allowed to vary between 4.5 and 6.5 bar because of the spring stiffness, resulting in a small flow field, see figure 5.2. It is therefore desirable to have a bigger flow field. A solution to the problem is to utilize pre compensators with anti saturation instead of common pre compensators. The flow across the main spool is then dependent on the pump pressure margin, ∆pp , instead of the resulting spring pressure, see equation (2.7). The compensator will make sure that the pressure drop across the main spool becomes exactly what is needed for the flow to pass by. Hence the pressure drop across the main spool can theoretically be whatever and the flow field will be infinitely large, see figure 5.6. 180 160 140 4.5 bar pressure drop 6.5 bar pressure drop Small pressure drop Large pressure drop Flow [l/min] 120 100 80 60 40 20 0 0 10 20 30 40 50 60 Command signal [%] 70 80 90 100 Figure 5.6: Flow field when using pre compensators with anti saturation Another solution is to utilize post compensators. That solution is however not considered in this master thesis, mainly because a post compensated valve is not available on the test rig. The reason why this is working is because the pump pressure is automatically adjusted by the system. If a higher ∆pp is needed to deliver all flow to the actuators the pump pressure will increase and vice versa. Observe that this implies only if the pump is displacement controlled. If the pump is pressure controlled the flow is automatically adjusted in order to maintain the system pressure. Observe also that the flow map or inaccuracy in the pump controller no longer is a problem. The compensators will make sure that all flow delivered from the pump reaches the actuators independent of the main spool restriction area. 5.4 Displacement Controlled System with Flow Sharing Capabilities 63 The pre compensator with anti saturation was originally designed to deal with the pump saturation problem. When sufficient flow cannot be delivered the compensator will share the flow in proportion to demand. Used in a displacement controlled system, the compensator will share the flow in every situation by adjusting the pressure drop across the main spool. Therefore the compensator will from now on be called flow sharing compensator. In a load sensing system the flow is controlled by the restriction area of the main spool. When the pump is displacement controlled and the valve is equipped with a flow sharing compensator this is not the case. The flow is then controlled by the pump and the valve will cause unnecessary pressure losses. It is therefore smart to increase the restriction area and reduce the pressure drop but still get the same flow, see equation (5.1). The main spool can hence always be manoeuvred to its end position and the pressure drop is adjusted to match the flow delivered from the pump, see figure 5.7. 180 160 140 Flow [l/min] 120 100 80 60 40 20 0 0 10 20 30 40 50 60 Command signal [%] 70 80 90 100 Figure 5.7: Flow field when manoeuvring the main spool to its end position In the following sections the simulation model of a displacement controlled system equipped with flow sharing compensators, see figure 3.21, will be utilized to validate the control principle. From now on the system will be referred to a displacement controlled system with flow sharing capabilities. 5.4.1 One Actuator In the simulation model the flow delivered from the pump is increased according to figure 5.8. The main spool is manoeuvred to its end position during the whole simulation and the load is kept at a constant level. The compensator will make sure that all flow is delivered to the actuator by increasing the pressure drop across the main spool. The pump pressure is therefore also increased when more flow is delivered from the pump, partly because the bigger pressure drop and partly because increased friction losses in the pipe connecting the pump and the valve. 64 Design of Displacement Controlled Systems 200 140 Pump pressure Pressure [Bar] Flow [l/min] Delivered flow 150 100 50 0 1 2 3 Time [s] 4 120 100 80 1 5 40 2 5 Pressure drop across main spool Pressure [Bar] Pressure [Bar] 4 10 Pump pressure margin 30 20 10 0 1 3 Time [s] 2 3 Time [s] 4 5 8 6 4 2 0 1 2 3 Time [s] 4 5 Figure 5.8: ∆p controls the flow 5.4.2 Two Actuators If two actuators are used simultaneously the compensators will make sure that the pressure drop across the main spools is the same. To get a correct flow distribution to the actuators the restriction area of the main spool can be used as a flow divider. The section with the highest flow demand can be manoeuvred to its end position as before and the other section should be manoeuvred in proportion to the flow demand. Because the pressure drop is the same across both main spools, the restriction area will determine the flow according to equation (5.1). This can be achieved by manipulating the command signals to the valves. When using common pre compensators a current corresponding to the command signal was sent to the valves. Here the command signals are recalculated in order to manoeuvre the section with the highest flow demand completely and the other in proportion to the flow demand. The original command signal is sent to the pump in order to deliver the flow demanded from the operator. A nice feature is that operator can decide the characteristics on the lift and tilt map. This is because the compensator will make sure that the pressure drop across the main spool is exactly what is needed for the flow to pass by. When testing this in the simulation model one actuator is activated and all flow delivered from the pump reaches that actuator. Then another actuator with a bigger flow need is activated. As seen in figure 5.9 the right amount of flow is delivered to both actuators because the main spools are manoeuvred in proportion to the flow demand. 5.4 Displacement Controlled System with Flow Sharing Capabilities 65 100 1.5 Demanded flow tilt Demanded flow lift Delivered flow tilt Delivered flow lift Position / max position Flow [l/min] 75 Tilt main spool position Lift main spool position 50 25 0 0 1 2 3 4 1 0.5 0 0 5 1 2 Time [s] 3 4 5 Time [s] Figure 5.9: Two actuators with different flow demand 5.4.3 Flow Forces In the previous simulations flow forces was not taken under consideration. In a real application this is not the case. When including flow forces in the simulation the flow delivered to the actuators might not be exactly as demanded. What happens is that one actuator gets more flow and the other less flow according to figure 5.10. This is however not a big problem because it will hardly be noticed in a real application. 100 1.5 Demanded flow tilt Demanded flow lift Delivered flow tilt Delivered flow lift Position/ max position Flow [l/min] 75 Tilt main spool position Lift main spool position 50 25 0 0 1 2 3 Time [s] 4 5 1 0.5 0 0 1 2 3 4 5 Time [s] Figure 5.10: Two actuators affected by flow forces This problem is not unique for displacement controlled systems. Also in load sensing systems, flow forces will have influence on the main spool position and thus the flow. The current to the cartridge valve and the pilot pressure together 66 Design of Displacement Controlled Systems with the tolerances of the components will also affect the main spool restriction area. 5.4.4 Position Feedback A way of solving this is to include a position feedback in the control loop. If the actual position of the main spool is known the current sent to the valve can be adjusted in order to achieve the reference position. If the same test as previous is made with a position feedback a correct flow distribution is achieved according to figure 5.11. Since a position sensor on the main spool is not available on the test rig this solution is left outside the scope of this master thesis. 125 1.5 Demanded flow tilt Demanded flow lift Delivered flow tilt Delivered flow lift Position/ max position Flow [l/min] 100 Tilt main spool position Lift main spool position 75 50 1 0.5 25 0 0 1 2 3 Time [s] 4 5 0 0 1 2 3 4 5 Time [s] Figure 5.11: Two actuators controlled by a position feedback 5.4.5 Different Loads In the previous simulations the force acting on the actuators has been equal. When simulation different loads the compensators should make sure that an equal pressure drop across the main spools is obtained. But according to figure 5.12 this is not the case. It is because the compensator at the heaviest load reaches its end position and it is therefore unable to maintain the same pressure drop as the other compensator. The flow across the main spool can be calculated according to equation (2.7). Since a part of ∆pp is throttled across the main spool, the other part will be throttled across the compensator at the heaviest load. The flow across the compensator can hence be calculated according to equation (5.3). Those equations are only valid if the compensator is in its control position. When a flow sharing compensator is utilized control position means that the compensator not reaches its end position. Lever [%] 100 Tilt command Lift command 50 0 0 1 2 3 4 5 Position/ max position 5.4 Displacement Controlled System with Flow Sharing Capabilities 67 2 Lift main spool position Tilt main spool position 1.5 1 0.5 0 0 1 2 Time [s] 4 5 0.5 Pressure drop across tilt main spool Pressure drop across lift main spool Position [m] Pressure [Bar] 10 5 0 0 3 Time [s] 1 2 3 4 5 Tilt actuator position Lift actuator position 0.4 0.3 0.2 0.1 0 0 1 Time [s] 2 3 4 5 Time [s] Figure 5.12: Two actuators with compensator in its end position s Ac1 2 1− ∆pp qc = Cq Ac ρ Ac2 (5.3) Since the flow across the main spool and the compensator is the same, the equations can be put together. s s Ac1 2 Ac1 2 1− ∆pp = Cq Ac ∆pp (5.4) Cq As ρ Ac2 ρ Ac2 When equation (5.4) is simplified a relationship between the restriction areas and the areas exposed to the control pressures is obtained according to equation (5.5). r Ac2 −1 (5.5) As = Ac Ac1 If the restriction area of the compensator is maximized and the compensator is designed like it is today the maximal allowed restriction area of the main spool can be calculated. r Ac2 As,allowed = Ac,max − 1 < As,max (5.6) Ac1 According to equation (5.6) the compensator cannot be in its control position while the main spool is fully open. One opportunity is to limit the manoeuvring of the main spool so that a bigger restriction area is not achieved. However, a decrease of the restriction area means an increase of the pressure drop and thus a decrease of the energy efficiency. When simulating this solution the compensator will not reach its end position and the same pressure drop across the main spools is maintained according to figure 5.13. Design of Displacement Controlled Systems 100 Lever [%] Tilt command Lift command 50 0 0 1 2 3 4 5 Position/ max position 68 2 Tilt main spool position Lift main spool position 1.5 1 0.5 0 0 1 2 Time [s] 4 5 0.5 Pressure drop across tilt main spool Pressure drop across lift main spool 20 Position [m] Pressure [Bar] 30 10 0 0 3 Time [s] 1 2 3 4 Tilt actuator position Lift actuator position 0.4 0.3 0.2 0.1 0 0 5 1 Time [s] 2 3 4 5 Time [s] Figure 5.13: Two actuators with different loads and decreased restriction area 5.4.6 Redesign of the Flow Sharing Compensator Another possibility is to redesign the compensator. As a first step the areas exposed to the control pressures can be changed. The restriction area of the main spool is plotted against the quota of the areas exposed to the control pressures. In the left plot in figure 5.14, it can be seen how a redesign will affect the maximal restriction area of the main spool. If the quota is decreased, the main spool can be manoeuvred to its end position. The interesting part is however how this will affect the pressure drop across the valve. The flow is kept at a constant level and ∆p is plotted against the main spool restriction area. 150 100 pressure drop across main spool allowed restriction area for main spool maximal restriction area for main spool 0.8 Pressure [−] Main spool restriction area [%] 1 equation (5.5) allowed restriction area for main spool maximal restriction area for main spool 0.6 0.4 50 0.2 0 0.2 0.3 0.4 0.5 0.6 Ac1/Ac2 [−] 0.7 0.8 0 25 50 75 100 Main spool restriction area [%] Figure 5.14: Redesign of the quota The right plot in figure 5.14 shows that a decrease of the quota and thus an increase of the restriction area implies a lower ∆p for the same flow. 5.4 Displacement Controlled System with Flow Sharing Capabilities 69 A second step in the redesign could be to increase the maximal restriction area of the compensator. A new optimal point can be found in the left plot in figure 5.15 and the pressure drop would decrease even more according to the right plot in figure 5.15. 150 pressure drop with present area maximal restriction area for main spool pressure drop with increased area 0.8 Pressure [−] Main spool restriction area [%] 1 equation (5.5) maximal restriction area for main spool equation (5.5) with increased area 100 0.6 0.4 50 0.2 0 0.2 0.3 0.4 0.5 0.6 Ac1/Ac2 [−] 0.7 0 0.8 25 50 75 100 Main spool restriction area [%] Figure 5.15: Redesign of the quota and the maximal restriction area Lever [%] 100 Tilt command Lift command 50 0 0 1 2 3 4 5 Position/ max position A redesign of the compensator would give additional energy savings but since the compensator available on the test rig is of original design this is not further investigated in this master thesis. When comparing figure 5.16 and 5.13, it shows the same performance but with a decreased pressure drop across the main spool. 2 Tilt main spool position Lift main spool position 1.5 1 0.5 0 0 1 2 Time [s] 4 5 0.5 Pressure drop across tilt main spool Pressure drop across lift main spool Position [m] Pressure [Bar] 10 5 0 0 3 Time [s] 1 2 3 4 Time [s] 5 Tilt actuator position Lift actuator position 0.4 0.3 0.2 0.1 0 0 1 2 3 4 5 Time [s] Figure 5.16: Two actuators with different loads and a redisigned compensator 5.4.7 Lowering Motion When making a lowering motion the velocity of the actuator is determined by the meter out restriction. This is due to the gravitational force pushing the actuator. 70 Design of Displacement Controlled Systems Because of that, the main spool is controlled in proportional to the command signal when making a lowering motion. To avoid cavitations the pump will deliver enough flow to the piston rod side. By controlling the main spool in proportional to the command signal no additional energy savings across the valve is obtained. But the energy savings concerning ∆pp is still there because the system will adjust the pump pressure to a minimum level. A way of getting additional energy savings while making a lowering motion is to utilize an unloaded lowering. Oil to the piston rod side will then partly be delivered from the reservoir instead of the pump. This solution is however not considered in this master thesis. 5.4.8 Cylinder is Unable to Move Problems might occur when a cylinder reaches its end position or by some other reason is unable to continue its movement. In a load sensing system the flow is changed automatically to maintain the system pressure. If a cylinder is unable to continue its movement, no flow is needed to that section in order to maintain the system pressure. Hence, the other actuators will not be affected and the right amount of flow will be delivered from the pump. In a displacement controlled system the pump will continue to deliver the flow demanded from the operator, even though a cylinder is unable to continue its movement. If the flow has nowhere else to go, it will go to another actuator resulting in an increase of the speed for that actuator. This is not desirable and a solution is required. One solution is to utilize port relief valves in the motor ports. When the system pressure reaches the cracking pressure for the port relief valve the flow will be throttled to the reservoir. No extra flow will then speed up the other actuators. This solution will however result in high energy losses since the flow is throttled to the reservoir from a high pressure level. It is also not desirable to set the cracking pressure for the port relief valves at the same level as the maximal allowed system pressure. A better solution is to utilize a simple position sensor on the cylinder. When the cylinder reaches its end position the flow demanded from the operator to that section can be cancelled. It means that the pump will decrease its displacement and only deliver the flow demanded to the other actuators. The flow demand is cancelled until the operator demands a movement in the opposite direction. This solution will save a lot of energy but is not further investigated in this master thesis. Chapter 6 System Improvements Verifying Measurements To verify the simulation model of a displacement controlled system with flow sharing capabilities the system has been implemented in the test rig. Since the same components as in a load sensing system is utilized no hardware changes is necessary. To get a proper comparison between a load sensing system and a displacement controlled system with flow sharing capabilities measurements has been made on the test rig. During the tests the main spool has been manoeuvred to its end position despite that it will affect the system operability. This is because the system potential concerning energy efficiency should be highlighted. If a displacement controlled system with flow sharing capabilities is implemented in a commercial application the compensator needs to be redesigned, see section 5.4.6. If the compensator is redesigned the main spool could be manoeuvred to its end position with maintained system operability. 6.1 Pump Pressure Margin Reduction In section 4.2.3 it was shown how the pressure losses in the pipe connecting the pump and the valve depends on the flow. In a load sensing system ∆pp is set to a constant value resulting in unnecessary pressure losses across the compensator. In a displacement controlled system with flow sharing capabilities ∆pp is continuously adjusted to a minimum level, see section 5.4. In figure 6.1, ∆pp as function of the flow is shown for a load sensing system and in figure 6.2 for a displacement controlled system with flow sharing capabilities. 71 72 System Improvements - Verifying Measurements 100 60 Position [cm] Lever [%] Lift command 50 0 0 1 2 3 4 Time [s] 5 6 20 0 0 7 1 2 3 4 Time [s] 5 6 7 40 Pressure [Bar] 150 Flow [l/min] Lift actuator position 40 100 50 0 0 1 2 3 4 Time [s] 5 6 Pump pressure margin 30 20 10 0 0 7 1 2 3 4 Time [s] 5 6 7 Figure 6.1: Pump pressure margin in a load sensing system 100 60 Position [cm] Lever [%] Lift command 50 0 0 1 2 3 4 Time [s] 5 6 20 0 0 7 1 2 3 4 Time [s] 5 6 7 40 Pressure [Bar] 150 Flow [l/min] Lift actuator position 40 100 50 0 0 1 2 3 4 Time [s] 5 6 7 Pump pressure margin 30 20 10 0 0 1 2 3 4 Time [s] 5 6 Figure 6.2: Pump pressure margin in a displacement controlled system 7 6.2 Pump Saturation 6.2 73 Pump Saturation To show how a displacement controlled system with flow sharing capabilities behaves in a saturated situation the same test as in section 4.3.1 has been made. Because the system is equipped with flow sharing compensators the flow should be shared proportionally between all active functions. As seen in figure 6.3 and 6.4 the system acts in the same way as a load sensing system with anti saturation but with a lower ∆pp when the pump is not saturated. 100 60 Position [cm] Lever [%] Lift and tilt command 50 0 0 1 2 3 4 Time [s] 5 6 1 2 3 4 Time [s] 5 6 7 40 Pressure [Bar] Pressure [Bar] Tilt actuator position Lift actuator position 20 0 0 7 100 Pump pressure 50 0 0 40 1 2 3 4 Time [s] 5 6 Pump pressure margin 20 0 0 7 1 2 3 4 Time [s] 5 6 7 5 6 7 Figure 6.3: Pump saturation in a load sensing system 100 60 Position [cm] Lever [%] Lift and tilt command 50 0 0 1 2 3 4 Time [s] 5 6 1 2 3 4 Time [s] 40 Pressure [Bar] Pressure [Bar] Tilt actuator position Lift actuator position 20 0 0 7 100 Pump pressure 50 0 0 40 1 2 3 4 Time [s] 5 6 7 Pump pressure margin 20 0 0 1 2 3 4 Time [s] 5 Figure 6.4: Pump saturation in a displacement controlled system 6 7 74 System Improvements - Verifying Measurements 6.3 Step Response Even though the response behaviour is outside the scope of this master thesis it is important to show a similar response compared to a load sensing system. Otherwise the comparison in section 6.4 cannot be made. The same test as in section 4.3.2 is made with a displacement controlled system with flow sharing capabilities. According to figure 6.7 the response in the systems is comparable. 100 60 Lift command Tilt command 50 Position [cm] Lever [%] 80 60 40 20 0 0 Lift actuator position Tilt actuator position 40 30 20 10 1 2 3 Time [s] 4 5 0 0 6 1 2 3 Time [s] 4 5 6 5 6 Figure 6.5: Step response in a load sensing system 100 60 Lift command Tilt command 50 Position [cm] Lever [%] 80 60 40 20 0 0 Lift actuator position Tilt actuator position 40 30 20 10 1 2 3 Time [s] 4 5 6 0 0 1 2 3 Time [s] 4 Figure 6.6: Step response in a displacement controlled system 6.4 Short Duty Cycle 75 100 50 Lift command both system Tilt command both system 40 Position [cm] Lever [%] 80 60 40 20 0 0 Lift actuator position, LS Lift actuator position, New system Tilt actuator position, LS Tilt actuator position, New system 30 20 10 1 2 3 Time [s] 4 5 6 0 0 1 2 3 Time [s] 4 5 6 Figure 6.7: Step response in both systems 6.4 Short Duty Cycle The final test when comparing a load sensing system with a displacement controlled system with flow sharing capabilities is a short duty cycle for a wheel loader application. This test is suitable because it is important to compare the two systems under realistic circumstances. Another type of standardized test could also be made but since the system is implemented in a wheel loader application the short duty cycle is the chosen one. Only the working hydraulics is considered in the measurements. Neither the steering nor the transmission has been taken under consideration. Figure 6.8: Short duty cycle [3] 76 System Improvements - Verifying Measurements When making a short duty cycle the wheel loader drives into the gravel pile to fill the bucket. The lift and tilt functions are then increased. The wheel loader will then drive backwards towards the reversing point and then towards the load receiver. The wheel loader will empty its bucket on the load receiver by decreasing the tilt function. Finally the wheel loader drives backwards towards the reversing point while the bucket is lowered in order to begin a new cycle, see figure 6.8 [3]. In order to compare a load sensing system with a displacement controlled system with flow sharing capabilities two identical tests need to be made. This is almost impossible and if the tests are not identical a proper comparison cannot be done. A solution to the problem is to make one test with the displacement controlled system. Because the performance is similar the exact same test could have been made with a load sensing system. The only thing that differs is the pump pressure margin, ∆pp . In a load sensing system, ∆pp is set to a constant value of 25 bar. Hence if the pump pressure is adjusted in test with the displacement controlled system in order to maintain a constant ∆pp of 25 bar, a similar test but with a load sensing system is obtained. A short duty cycle test with a load sensing system has also been made to verify that ∆pp in fact is 25 bar. As seen in figure 6.12 a constant ∆pp of 25 bar is a good approximation. 100 Lift command Tilt command Lever [%] 50 0 −50 −100 0 5 10 15 20 25 30 35 Time [s] Figure 6.9: Command signals using a load sensing system 0.5 Lift actuator position Tilt actuator position Position [m] 0.4 0.3 0.2 0.1 0 0 5 10 15 20 25 30 35 Time [s] Figure 6.10: Actuator positions using a load sensing system 6.4 Short Duty Cycle 77 250 Pump pressure Load pressure Pressure [Bar] 200 150 100 50 0 0 5 10 15 20 25 30 35 Time [s] Figure 6.11: Pump- and load pressure using a load sensing system 60 Pump pressure margin Average pump pressure margin Pressure [Bar] 50 40 30 20 10 0 0 5 10 15 20 25 30 35 Time [s] Figure 6.12: Pump pressure margin using a load sensing system In the following figures a short duty cycle using a displacement controlled system with flow sharing capabilities is shown. The corresponding test using a load sensing system is also shown in the same figures. As seen in figure 6.18, the energy consumption can be decreased with 14 % during a short duty cycle when using a displacement controlled system instead of a load sensing system in this application. 78 System Improvements - Verifying Measurements 100 Lift demand Tilt demand Lever [%] 50 0 −50 −100 0 5 10 15 20 Time [s] 25 30 35 40 Figure 6.13: Command signals in a short duty cycle 0.7 Lift actuator position Tilt actuator position 0.6 Position [m] 0.5 0.4 0.3 0.2 0.1 0 0 5 10 15 20 Time [s] 25 30 35 40 Figure 6.14: Actuator positions in a short duty cycle 250 Pump pressure, displacement controlled system Pump pressure, load sensing system Load pressure Pressure [Bar] 200 150 100 50 0 0 5 10 15 20 Time [s] 25 30 35 40 Figure 6.15: Pump- and load pressure in a short duty cycle 50 Pump pressure margin, displacement controlled system Pump pressure margin, load sensing system Pressure [Bar] 40 30 20 10 0 0 5 10 15 20 Time [s] 25 30 35 40 Figure 6.16: Pump pressure margin in a short duty cycle 6.4 Short Duty Cycle 79 30 Power, displacment controlled system Power, load sensing system Power [kW] 25 20 15 10 5 0 0 5 10 15 20 Time [s] 25 30 35 40 Figure 6.17: Power consumption in a short duty cycle 200 Energy, displacment controlled system Energy, load sensing system Energy [kJ] 150 100 50 0 0 5 10 15 20 Time [s] 25 30 35 40 Figure 6.18: Energy consumption in a short duty cycle 80 System Improvements - Verifying Measurements Chapter 7 Summary & Conclusions A displacement controlled system is an alternative to a load sensing system when energy efficiency is a vital issue. Except for the pump, the exact same components can be utilized and no additional sensors are necessary. The increased energy efficiency is due to a lower pump pressure margin since the system will compensate for pressure losses between pump and valve itself. Hence, no unnecessary energy losses across the compensator will occur. Originally the idea of a displacement controlled system was to match the manoeuvring of the main spool with the flow delivered from the pump using common pre compensators. Such system design would require a very good flow map and an exact knowledge of the current shaft speed and volumetric efficiency of the pump. The flow map would also be different depending on the application and the tolerance of the components. This is not practically achievable in all kinds of applications. By using flow sharing compensators instead of common pre compensators all these problems will be eliminated and additional energy savings across the main spool is enabled. The compensator will make sure that the pressure drop across the main spool becomes exactly what is needed for the flow to pass by independent of the main spool restriction area. Hence the flow delivered from the pump does not need to be matched against the manoeuvring of the main spool. Neither the flow map nor the shaft speed nor the volumetric efficiency is then a problem. Additional energy savings across the main spool can be achieved by manoeuvre the main spool to its end position independent of the flow delivered from the pump. A minimal pressure drop across the main spool for the corresponding flow is then obtained. In a displacement controlled system with flow sharing capabilities there is hence no unnecessary energy losses. The compensator at the heaviest load will be completely open and also the main spool with the highest flow demand. If further energy savings should be obtained, additional pumps or transformers need to be utilized. In a load sensing system there is no unnecessary pressure drop across the compensator when maximal flow is delivered from the pump. This is because the high 81 82 Summary & Conclusions pressure losses in the pipe connecting the pump and the valve, see section 4.2.3. If the operator manoeuvres the spool to its end position there is no unnecessary pressure losses across the main spool either. Hence when maximal flow is delivered and the main spool is completely open, the energy efficiency in a load sensing system will be equal to a displacement controlled system with flow sharing capabilities. Otherwise, the energy efficiency will be higher in a displacement controlled system. 40 Pump pressure margin, displacement controlled system Pump pressure margin, load sensing system 35 Pressure [Bar] 30 25 20 15 10 5 0 0 10 20 30 40 50 60 Flow [l/min] 70 80 90 100 110 Figure 7.1: Pump pressure margin in load sensing and displacement controlled As seen in figure 7.1, the pump pressure margin must be the same in both systems if maximal flow is delivered from the pump. Otherwise it can be decreased a lot. In an application that not uses all available pump capacity during its duty cycle, the energy efficiency can be increased if a displacement controlled system is utilized instead of a load sensing system. The wheel loader application used in this master thesis could for example decrease its energy consumption with 14 % during a short duty cycle. In extreme applications using all available pump capacity the energy efficiency cannot be increased with a displacement controlled system. Minimal energy losses across the compensator and the main spool are already achieved with a load sensing system. But there are other advantages with a displacement controlled system. Even though the energy efficiency cannot be increased there is still a potential of better response and less oscillations. To summarize, the proposed displacement controlled system with flow sharing capabilities has better or equal energy efficiency compared to a traditional load sensing system. It has also a potential of better response and less oscillations. To switch from a load sensing system would require a displacement controlled pump and an electronically controlled valve. Neither a flow map nor the accuracy of the pump nor additional sensors needs to be considered. Chapter 8 Future Work • The potential of a better response when controlling the displacement of the pump needs to be studied, see section 5.2.1. For example, an external pilot pressure could be attached to the control valve of the pump. • The potential of less oscillations also needs to be studied, see section 5.2.2. • The flow sharing compensators cannot maintain a constant pressure drop across all main spools because it will reach its end position. An investigation regarding how to redesign the compensator needs to be made in order to get a correct flow distribution to several actuators, see section 5.4.6. • In this master thesis only common pre compensators and flow sharing compensators have been studied. However, it would be interesting to study post compensators as well. • To deal with flow forces acting on the main spool a position feedback can be utilized, see section 5.4.3 and 5.4.4. This will also improve the flow distribution if several actuators are activated. • During a lowering motion there are opportunities to get additional energy savings when controlling the displacement of the pump. For example, an unloaded lowering might be utilized, see section 5.4.7. • When the cylinder reaches its end position a position sensor can cancel the flow delivered from the pump to that actuator, which means energy savings, see section 5.4.8. • If unknown functions are connected to the same pump as the working hydraulics, problems might occur when controlling the displacement. A study regarding this problem needs to be done. • Improve the timing between the pump and the valve by sending signals in the right moment. Thus preventing the valve to rush ahead and open before the pump can provide a flow. • Let professional drivers test the system in different applications. 83 84 Future Work Bibliography [1] Mobile Hydraulic Technology. Parker Hannifin, 1999. [2] Milan Djurovic. Energiesparende Antriebssysteme für die Arbeitshydraulik mobiler Arbeitsmaschinen Elektrohydraulishes Flow Matching. Shaker Verlag Aachen, 2007. [3] Reno Filla. Operator and machine models for dynamic simulation of construction machinery. LiTH, 2005. [4] Institutionen för konstruktions & produktionsteknik. Formelsamling i Hydraulik och pneumatik. Linköpings Tekniska Högskola, 1995. [5] Per-Anders Kumlin. Implementation of a flow controlled hydraulic work system. Parker Hannifin, 2008. [6] Christoph Latour. Electrohydraulic Flow Matching: The next generation of load-sensing controls. Bosch Rexroth, 2007. [7] Herbert E. Merritt. Hydraulic Control Systems. John Wiley & Sons, New York, 1967. ISBN 0-471-59617-5. [8] Bo Nilstam. Oral, December 2008. [9] K-E. Rydberg O. Olsson. Kompendium i hydraulik. konstruktions- & produktionsteknik, 1993. 85 Institutionen för 86 Bibliography Appendix A Hydraulic Schematic of a L90LS Valve 87 88 Hydraulic Schematic of a L90LS Valve
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