University of Central Florida

Retrospective Theses and Dissertations

Masters Thesis (Open Access)

Selection Considerations For a Servovalve

1977

Frank J. Niemas Jr.

fniemas@comcast.net

Find similar works at: http://stars.library.ucf.edu/rtd

University of Central Florida Libraries http://library.ucf.edu
Part of the Engineering Commons
STARS Citation
Niemas, Frank J. Jr., "Selection Considerations For a Servovalve" (1977). Retrospective Theses and Dissertations. Paper 364.

This Masters Thesis (Open Access) is brought to you for free and open access by STARS. It has been accepted for inclusion in Retrospective Theses and
Dissertations by an authorized administrator of STARS. For more information, please contact lee.dotson@ucf.edu.

SELECTION CONSIDERATIONS
FOR A SERVOVALVE

B.E.,

FRANK J. NIEMAS, JR.

Stevens I n s t i t u t e o f Technology, 1968

RESEARCH REPORT
Submitted i n p a r t i a l f u l f i l lment o f the requirements f o r
the degree o f Master o f Science i n Engineering i n
the Graduate Studies Program o f
Florida Technological University

Orlando, F l orida
1977

ABSTRACT

Servovalves are a key factor in determining the performance characteristics of an electrohydraul ic position servo. This paper examines
the interret ationshf ps between servoval ve parameters and system requi rements.

A brief description of the configuration and operation of a typical servoval ve is presented.

Key servoval ve parameters are identified,

defined, and discussed. System performance considerations are identiffed, and the interrelationships between system requirements and servo-

valve parameters are exami ned.

Examples of servovalve parameters for

missile, aircraft and industrial systems are given to illustrate the

effect of system requirements on a servovalve. Finally, general guide1 ines for selecting and specifying servovalve parameters are given.

ACKNOWLEDGEMENTS
I n order t o produce t h i s report, I had the help o f many people.
The number o f people who helped me i n many ways, b i g and small, was
extremely g r a t i f y i n g ; b u t unfortunately, space does n o t permit l i s t i n g
a l l o f them.

To my f r i e n d s and associates a t M a r t i n M a r i e t t a and FTU,

my sincere thanks.

Because o f t h e i r special e f f o r t s , I wish t o personally thank cert a i n individuals.

Jr.,

I am indebted t o my advisor, D r . Richard Rapson,

f o r h i s advice and guidance throughout the preparation o f my

report, and t o the o t h e r members o f my committee, D r . C. E. Nuckolls

and Dr. 6. Ventre, f o r t h e i r time and t h e i r comments.

I thank Ed

Osczowinski o f Moog, Inc. f o r being a source o f specialized information

which i s o n l y a v a i l a b l e from a servovalve manufacturer.

Without the

e x c e l l e n t work o f my t y p i s t s , Cora Oldroyd and Louise Cleary, the t e x t

would be u n i n t e l l i g i b l e .

F i n a l l y , special thanks are due my wife,

A r l ine, w i t h o u t whose encouragement and patience I woul dn ' t be i n

graduate school i n the f i r s t place, and t o my daughter, Heather Marie,

j u s t f o r being sweet.

TABLE OF CONTENTS

.......................
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . .
LISTOFTABLES . . . . . . . . . . . . . . . . . . . . . . . .
LISTOF ILLUSTRATIONS. . . . . . . . . . . . . . . . . . . . .

ACKNOWLEDGEMENTS

iii
iv
v
vi

CHAPTER

....................
Description o f a Servovalve. . . . . . . . . . . . . . .
Appl i c a t i o n o f a Servovalve. . . . . . . . . . . . . . .

I. I n t r O d u c t i o n . .
11.

111.

IV.
V.

VI.

........
by a Servovalve . . . . . .

4
10

D e f i n i t i o n o f Key Servoval ve Parameters.

14

System Requirements Affected

27

I n t e r r e l a t i o n s h i p s o f System Requirements and

................
V I I. Example o f System Requirements P r i o r i t i e s . . . . . . . .
V I I I . General Guidelines and Conclusions . . . . . . . . . . .
FOOTNOTES. . . . . . . . . . . . . . . . . . . . . . . . . . .
SELECTED BIBLIOGRAPHY . . . . . . . . . . . . . . . . . . . . .
Servoval ve Parameters.

29

47

51
55

57

LIST OF TABLES

1.

2. Servovalve Materials Sumnary

3.

.....
...............

Typical Dimensions and Clearances in a Servovalve

8
9

Cleanliness Classification by Number of Particles in

100 Milliliter Flul'd Sample

...............

33

4. Representative Servovalve Parameters for Various

Appl ications

......................

50

LIST OF ILLUSTRATIONS
1

.
3.
2

4.
5

6
7

.
9.
10.
8

...................
Application of a Servovalve in a Position Servo . . . . . .
Block Diagram of a Position Servo . . . . . . . . . . . .
Representative Flow Curve . . . . . . . . . . . . . . . . .
Definition of Null and Normal Flow Regions . . . . . . . .
Pressure Gain Characteristics. . . . . . . . . . . . . . .
Zero Lap Spool . . . . . . . . . . . . . . . . . . . . . .
Overlapped Spool . . . . . . . . . . . . . . . . . . . . .
Underlapped Spool . . . . . . . . . . . . . . . . . . . . .
Lap Defined in Terms of Flow Curve . . . . . . . . . . . .
Servoval ve Schematic

11
13

17
18

21

22
24

25
26

1 1 . Effect of Fluid Contamination Level on Servovalve

........................
12. Effect of Dither on System Output . . . . . . . . . . . . .
13 . E f f e c t of Lap on Pressure Gain . . . . . . . . . . . . . .
14. Block Diagram of Position Servo . . . . . . . . . . . . . .
15. Root-Locus Plot for System of Fig . 14. . . . . . . . . . .
16. Typical Fl ow-Load Characteristics. . . . . . . . . . . . .
Threshold

32
35
37
39

41
45

CHAPTER I

I MTRODUCTION

Electrohydraul ic servo systems were original ly developed for aircraft and missiles where their efficiency, compactness and high response
capabilities were distinct advantages.'

As the technology of electro-

hydraul ic servos developed, the appl ication of such systems broadened,

encompassing machine tools, mobile equipment, computer disc accessing
controls, and many other applications where precise positioning of a
1 oad is required.

While the application of these servosystems has resulted in a wide

range of force response, rate, environment, and size requirements, the
problems of the system designer are essentially the same, regardless of
the application. The system designer is presented with a set of performance requirements for a given system, and must develop a system to
meet these requirements. Depending on the specific system, part of the
designer's job will be to design components specifically to meet the
requirements of his system. With many components, however, the technology required to produce specialized components requires unique experience and manufacturing capabilities, not readily available to the
designer. In these cases, it is impractical and uneconomical to design
and bui 1 d such i tems.

Instead, components such as these are purchased

from vendors who have the technical expertise and manufacturing capabi lity to produce them. In this case, the designer's job is to determine

component requirements from the system requirements, and, together w i t h

a vendor, t a i l o r an " o f f the s h e l f " i t e m t o meet the system requirements.
An e l ectrohydraul i c servoval ve i s among the most important procured
components.

Regardless o f appl i c a t i o n , a11 e l ectrohydraul i c servosys-

terns u t i l i z e a servovalve; i t i s t h e element t h a t provides the l i n k

between the e l e c t r i c a l and hydraulic elements o f the system.
Servovalves a r e such complex and unique devices t h a t they are
almost always procured r a t h e r than b u i 1t in-house.
S p e c i f i c a t i o n and s e l e c t i o n o f a servovalve i s one o f the system
designer's most important tasks.

Dynamic response, r a t e capabi 1ity, and

accuracy o f the system are t o a l a r g e degree determined by the performance o f the servovalve.

The converse i s a l s o true; the s p e c i f i c re-

quirements o f a system w i l l determine many aspects o f t h e c o n f i g u r a t i o n

of the servoyal ve.

The system designer should recognize the i n t e r r e l a-

t ionshi p between system and servoval ve parameters.

This paper w i l l attempt t o b r i e f l y examine t h i s i n t e r r e l a t i o n s h i p .

Important servovalve character1s t i c s w i 11 be i d e n t i f i e d and defined, and

key system considerations w i l l be discussed.

As w i l l be shown i n the

t e x t , the f j n a l c o n f i g u r a t i o n o f a valve and a system w i l l be the r e s u l t

o f many tradeoffs.

It w i l l be shown t h a t a change i n one servovalve

parameter t o improve system performance may a f f e c t another f a c e t o f

valve behavior which may i n t u r n adversely a f f e c t another area o f system
performance.

Likewise, small chqnges i n system requirements may g r e a t l y

influence the s u i t a b i l ity o f a given servoval ve c o n f i g u r a t i o n t o meet

<-??a
.

sysrem necas.

It i s the job o f the system designer t o make these trade-

offs.

Due t o the b r e v i t y o f the r e p o r t and the complexity o f the subject,

t h i s paper w i l l n o t consider a l l aspects o f t h i s i n t e r r e l a t i o n s h i p i n
great detai 1.

However, i t i s intended t o i11u s t r a t e the more important

i n t e r r e l a t i o n s h i p s which e x i s t and tradeoffs which must be made.

CHAPTER I1
DESCRIPTION OF A SERVOVALVE
Just as there is a great variety in the requirements and configurations of electrohydraulic servosystems, there are a great number of
servoval ve configurations. Servovalves may be single stage or mu1 tistage. They may be incorporate torque motors or solenoids. They may
use spool valves, flapper valves, jet pipe valves, or some other type of
variable hydraul ic control element.

In function and terminology, they

are all essentially similiar. Most of the material in this report will
apply to servovalves in general. In order to explain the particular
basic principles of operation and to give specific examples, specialized
information in this report is based on the Moog Series 30 valve. This
valve was chosen for illustrative purposes for several reasons. It is a
widely used valve in aerospace applications, and is representative of
modern servovalve design.

It is similar to valves produced by other

vendors. There is a large amount of data available on this valve.

A schematic of this servovalve is presented in figure 1. The

Series 30 valve is a two-stage servovalve. The first stage is a double
nozzle flapper valve control led by an electrical torque motor. The
second stage is a four way spool valve whose output flow at a fixed
valve pressure drop is proportional to spool displacement from null.
Feedback of second stage spool position is accomplished by a cantilever
feedback spring attached to the armature.

6
The - w r v o v a l v e i s connected t o system supply and r e t u r n pressure by
p o r t s on the mounting face o f the servovalve.

Supply pressure i s sup-

p l i e d t o the output spool t o be metered t o t h e two c o n t r o l p o r t s and

a l s o i s f i l t e r e d and supplied through two f i x e d i n l e t o r i f i c e s t o t h e
two v a r i a b l e o r i f i c e s created by the nozzle-flapper arrangement.

The

pressure developed i n the area between the f i x e d and v a r i a b l e o r i f i c e s

i s appl i e d t o both ends o f the second stage spool.

With no i n p u t signal

t o the torque motor, the two v a r i a b l e o r i f i c e s are equal , t h e pressure

on both ends o f the spool are equal, and no motion o f the spool occurs.
No f l o w i s supplied t o e i t h e r c o n t r o l port.

As a command signal i s

applied t o the torque_ .motor,

- _
a torque i s developed on the armature which
-:<:*,
pw':.-r - ' . $2$*+nA'.* &&-.&&-&~q~s&pp@gp
.q,...d
- ::--&;+&&~~-;.,
-- . -.
: causes a r o t a t i o n o f t h e armature about i t s f l e x u r e t&e ~ u $ ~ o r t .This

.Y,L

.C-

motion r e s u l t s i n two d i f f e r e n t s i z e v a r i a b l e o r i f i c e s and hence a

pressure imbalance on t h e two ends o f t h e output spool.
imbalance produces a n e t f o r c e

t o move t h e spool.

The pressure

As the spool moves,

t h e feedback spring applies a torque proportional t o spool p o s i t i o n t o

t h e armature/flapper.

This torque opposes the torque motor torque and

increases w i t h spool p o s i t i o n u n t i l the two torques cancel o u t and a

p o s i t i o n o f e q u i l i b r i u m i s reached.

The armature/flapper i s now cen-

tered, the v a r i a b l e o r i f i c e s are again equal, and no n e t f o r c e i s

present t o move the spool from i t s new p o s i t i o n .
spool i s supplyin

A t t h i s p o s i t i o n , the

o one o f the c o n t r o l ports, w h i l e

t h e other c o n t r o l p o r t i s connected t o system r e t u r n pressure.

By t h e

process out1 ined above, a c o n t r o l f l o w proportional t o i n p u t signal i s

suppl fed by the servovalve.

The exp~anatlonabove is a simplication o f the operational problems

involved. In real i ty, servovalves are complex and expensive components.

In order to gain some insight into their nature, tables 1 and 2 are
presented. 2
Tab1 e 1 presents typical critical internal dimensions and clearances. The rnagni tude of these djmensions and clearances serve to indicate the precisjon machining and unique manufacturing capabi 1i ties
required to produce a servovalve. Some of the critical dimensions are
measured in mlll ionths of an inch and provide an indication of why fluid
contamination or thermal effects can drastically affect valve behavior.

Table 2 i s a listing of the various materials used in a servovalve.

The materials have been selected on the basis of wear, strength, magnetic characteristics, and other requirements. They indicate the expense and variety of fabricatlon techniques involved in production of a
servovalve. A1 so, the divers1 ty of materials used should indicate the
possi bil ity o f adverse thermal effects due to differential expansion.
The expl anation and characteritation of servoval ve operation pres-

ented above only presents the basic principles involved, but it should
be adequate to understand the information presented in the following

sections.

TABLE 1

TYPICAL DIMENSIONS AND CLEARANCES I N A SERVOVALVE

Dimension
Air gap spacing (each gap)

Maximum a m t u r e motion i n a i r gap

I n l e t o r i f i c e diameter
Nozzle diameter
Nozzle-flapptw maximum opening

Drain orifkt dfameter

g radial clearance

radial clearance

Thousandths of an Inch
10 t o 15

+3
5 t o 10

TABLE 2

SERVOVALVE MATERIALS SUMMARY

Component Part

Materi a1

Body, end caps, and accessories

17-4 PH stainless steel

Spool and bushing

Flexure tube
Pol epieces and armature
Magnets

Feedback w i rn
Torque motor cover

400-C stainless steel

Beryl 1 i urn copper
4750 nickel -i
ron steel
Alnico V1
17-7 stainless steel

Anodized a1 umi num a1 1 oy

CHAPTER I11
APPLICATION OF A SERVOVALVE
While the details of specific applications of servovalves can vary,
conceptually they are the same. Figure 2 describes schematically the
application of a flow control servovalve in a position servo.
The function of a position servo is to accurately position a load
in response to an electrical command signal. The elements shown in
figure 2 are present in all position servos. A hydraulic power supply
is needed to provide hydraul ic fl uid under pressure to move the 1 oad.
The actuator is the device employed to convert the hydraulic energy into
motion of the load. The servovalve is the device which converts the
electrical signals into controlled fluid flow to the actuator. In most
systems, a servoamplifier is required to drive the servovalve. An electrical feedback element senses actual position of the load. Feedback is
desirable in any control system for enhanced accuracy and response, and
absol utely necess

1 ectrohydraul i c servo-

which will be dis-

valve because

load at a given commanded position, the position

cussed 1 ater.

servo will maintain the position of the load until the command signal
changes .
As the command signal changes, the difference between the command
and input signals increases. These two signals are compared to produce

an error s,ignal

The error signal is processed in the servoampl ifier to

12

drive the-servovalve, causing displacement of the load toward the new

camnanded position. As the load moves, its position is sensed by the
feedback element. The difference between command and input is reduced
by this action, and when the error is sufficiently close to zero, the
1 oad motion ceases and the system reaches an equi 1i brium eondi tion. Any

disturbance tending to move the load from its equilibrium position will
generate an error signal to restore the load, and the system will tend
to remain at its camnanded position until the input c o m n d -is changed.
This concept i s shown schematically in the system b l w k diagram of
figure 3.
It can be seen from this simple explanation that the servovalve is
a critical element of a position servo. To a large extent, it determines the performance o f a posltion servo. In the following chapters,
key servovalve parameters will be defined, and their effect on the
performance o f a position servo will be examined.

CHAPTER I V
DEFINITION OF KEY SERVOVALVE PARAMETERS
Specifying a servovalve f o r use i n a c o n t r o l system can be complex.
A great many parameters have t o be specified, and i n t h e past, there was

no general agreement among the various servovalve manufacturers and

among servovalve users on standard terminology.

In an e f f o r t t o provide

standard terminology and t e s t procedures, the Society o f Automotive

Engineers (SAE) has w r i t t e n a document t o a i d i n the s p e c i f i c a t i o n o f
servoval ves 3

This document attempts t o cover a l l facets o f servovalve s p e c i f i cation.

As such, much o f i t s contents are outside t h e scope o f t h i s

report.

It does d e f i n e the key measures o f servovalve performance which

w i l l be discussed i n t h i s chapter.

Servovalve parameters which are

covered i n t h i s r e p o r t w i l l be defined i n terms o f the d e f i n i t i o n s used

by the SAE. - -..-

/
?
/
f

--

---i".-.J

L._

-.
.

./

._

--

I Looking a t a servovalve a t t h e component l e v e l , i t s i n p u t i s an

'..*
*-*----.e-

C-

__

._, -

nu.

..

"'7

t&PecpC-&.16(rk'

e l e c t r i c current, and i t s output i s hydraulic f l u i d f l o w a t

This i s n o t the t o t a l f l o w supplied t o t h e

valve.

For the example valve discussed e a r l i e r , some o f the f l o w sup-

p l i e d t o the valve goes t o the f i r s t stage t o be used t o p o s i t i o n the

second stage s p o o h \ ~ h i s f i r s t stage f l o w i s ported t o s y s t

f-

r s through the metering edges o- f- the

~$agespop_l
__.second
. -*#
- ---- ---. --.- ____
- -II

/--

-/.-.-*

return

I n additionbsdne f l u i d

and does n o t t r a v e l through t h e c o n t r o l ports.

--*--d

--*

I"C..

"*I--(

-,m

"--.I"

null u - a l s o between the spool sleeve and body.

Only the flow actu-

ally delivered to the control ports is defined as control flow.

Since the second stage of the servovalve i s a Cway spool valve,
the relationship between control flow and spool uncovered slot area
(proportional t o spool posi t i o n ) i s expressed as foll ows: 4

= CA

r/m

111.1

where
Q

output flow

dischargecoefficient

Uncovered slot area

A P.
._,.

= valve pressure drop (supply pressure minus return

\:.

pressure m i nus 1oad pressure drop)

P

mass density

This indicates that for a given spool position, a servovalve represents

a constant orifice opening.5 For a servovalve, the spool orifices can
be considered sharp-edged orif ices.

For sharp-edged orif ices and

turbulent flow, C = 0.611 .6 For petroleum based fluids, equation 111.1

can be written as:

Clearly, servovalve control flow is proportional t o the square root of

the valve pressure drop. Since the f i r s t stage controls the second
stage spool position, and since flapper position is proportional t o
input current, the relationship between i n p u t current and control flow
i s expressed as: 7

where
i n p u t current

= valvesizingconstant

,-"'.-'

"I

//

For good system perfomnce, i t i s desired that thekntro~floy/ be

proportional to i n p u t currant. The means for specifying and/or veri----.

i c i s t h e G u r v e , an example of

fyi na

-----""-..""-..""-.---.--__.-

-infigure4.
a g

This i s a p l o t o f c
/

--a e

n.L

The
. flow curve usually

shows the effect o f valve hysteresis during a complete cycle, so the

locus o f midpoints o f the flow curve, called the normal flaw curve, i s
used t o evaluate servovalve flow behavior. The closer this curve i s to
a straight line, the more desirable the normal flow curve i s from the

standpoint of system performance.

The slope of the normal flow curve i s defined as the n o m l flow
gain of a servovalve. When examining servovalve flow gain, there are
two regions of interest, as shown i n figure 5, the n u l l region and the
normal flow region.

The null region i s that area of low i n p u t current

where flow i s affected by the relative spacing of spool edges and s

/----(spool

lap); beyond that i s the normal flow regions.

Due to

.
I

>-*-lap

effects, flow gains i n the two regions are ordinarily not

'
.
.

equal. % flow gain can vary from 50% to 200% of normal flow

In an ideal valve, control flow is directly proportional to input

current, so that a t zero i n p u t current, control flow is zero.

In a real

valve, such i s not the case. As can be seen in figure 4, the flow curve
i s generally shifted so that the i n p u t current required for zero control
flow i s not zero. N u l l bias i s defined as the i n p u t current, excluding

Fig. 4.

Representative Flow Curve

Input Current

Fig. 5. Deftnition of Null and Normal Flow Regions

the effects of &&ve

h h y t e r e ! required to b r i n g the valve to nu1 1 .

In almost all cases, servovalves exhibit null bias.'

This explains why

servovalves are generally used i n a closed loop system; w i t h o u t feedback

to generate an error signal, a control system w i t h a zero i n p u t command
would go hard over.
In examining the flow curve of figure 4, the hysteresis effects can
-*~
,

be seen. When appl ied to servoval ves,$&res

,--.

L.IY.".+-

i s i s defined
-.- la77fae
,c-w.

,.--*-.

difference i n valve i n p u t currents require4,./b produce the valve output

dfl,*

"".
-

*rzl

.--rur^%lu^

u u . r ~ ~ . . 2 . . " . -.sic--*-

during a sing1e c y c u M . ~ & J v i n p ucurrent.

t
,-..
c------

Y-w*-v~~.~*

*. *,

.-,. ,'.

sr.,

<..,

Hysteresis measurements
-

are taken a t a cycling rate low enough so that dynamic effects are
unimportant. Hysteresis 7 n a servovalve i s a result of electromagnetic
sent i n a valve. 10
hold i n a s e r y e d v e i s essentially a measure of the
\

\--

n present in the second stage of a servovalve.

I t i s defined as

the increment o f i n p u t current required t o produce a change i n valve

output.

I t i s normally specified as the current increment required t o

revert from a condition of increasing o u t p u t to a condition of decreasing output.

As mentioned previously, a desirable servoval ve property i s that

output flow be directly proportional to i n p u t current, i.e., the re-

P"PPu t

lationship betwee

current and output flow should be a straight

line r e l a t i o n s h i w Linearity i s a measure of this property.

I t is

defined as the deviation of the normal flow curve from the normal flow
gain line, as shown i n figure 4.
As previously explained, not a l l the flow supplied t o a servovalve

exists as control flow.

Some of the entering supply i s transferred to

+
-

system return.

-.---*

20

This i s the servovalve leakage f l o w . ~ a k a ~ T ' i s

composed o f three components.

The f i r s t o f these i s f i r s t stage

hydraulic a m p l i f i e r flow, necessary t o p o s i t i o n the second stage o f the

valve.

The second c o n t r i b u t o r i s leakage i n the second stage spool.

i s s i g n i f i c a n t around the n u l l p o s i t i o n o f the spool and i s

A third

c o n t r i b u t o r t o leakage i s laminar f l o w leakage between the valve body

and bushi-ng.

The leakage f l o w exclusive o f spool n u l l leakage i s re-

f e r r e d t o as t a r e flow.
While t h e , r e l a t i o n s h i p between i n p u t c u r r e n t and output f l o w i s
e s s e n t i a l l y a l i n e a r one, the r e l a t i o n s h i p between i n p u t c u r r e n t and
/1

output pressure i s a non-linear o n e . v G g h i s defined as the

L
r a t e o f change o f load pressure drop
i n p u t c u r r e n t w i t h the c o n t r o l

p o r t s blocked.

Figure 6 presents a t y p i c a l pressure gain c h a r a c t e r i s t i c

f o r a servovalve.

Pressure gain i s u s u a l l y s p e c i f i e d as the slope o f

the curve o f load pressure drop vs. c u r r e n t between t40% o f maximum

1oad-pressure drop.
I n the output spool o f a servovalve a t i t s n u l l position, the
r e l a t i v e a x i a l p o s i t i o n between the f i x e d and movable f l o w metering
edges, c a l l ed 1ap, has a great in f 1uence on servoval ve performance.
Figures 7, 8, and 9 present a schematic diagram o f a spool i n r e l a t i o n
t o the output p o r t s i n the valve sleeve.
exist.

Three possible conditions

Figure 7 i l l u s t r a t e s a spool e x h i b i t i n g zero lap.

I n this

s i t u a t i o n , a t the nu1 1 position, the spool lands are e x a c t l y the same

s i z e and coincident w i t h the supply and r e t u r n pressure p o r t s on the
valve bushing.

Neglecting a x i a l clearance, t h i s c o n d i t i o n would r e s u l t

Slope i s Pressure
Gai n

Load Pressure Drop

with Control Ports
.

Blocked

40% .

Input Current

100%
'Gain Characteristics
'

-, .

I , .

'

.
,

. -%.

Spool lands j u s t
cover bushing s l o t s

Return

Fig. 7.

Zero Lap Spool

i n no control flow o r spool leakage a t nu11.

Any movement o f the spool,

however small, would instantaneously r e s u l t i n flow t o the control

ports.

I n a valve w i t h zero lap, the f l o w gain i n the n u l l region i s

the same as the f l o w gain i n the normal f l o w region, r e s u l t i n g i n a

l i n e a r flow curve. 13
Figure 8 shows a condition o f overlap.

I n t h i s case, the spool

land width i s greater than the bushing slop width.

i s zero c o n t r o l flow a t n u l l .

The r e s u l t , again,

However, i n the case o f overlap, a f i n i t e

amount o f spool motion must occur before the bushing s l o t s are uncovered
and flow t o the control p o r t occurs.

I n t h i s case, flew gain i n the

14
n u l l region i s less than the normal flow gain.
The t h i r d possible l a p condition i s underlap.

As shown i n f i g u r e

9, underlap i s t h a t condition when spool land width i s less than bushing

s l o t width.

Under these conditions, control and r e t u r n and supply ports

I n an underlapped valve, n u l l flow

gain i s greater than normal flow gain. 15
are comunicating, even a t n u l l .

When applied s p e c i f i c a l l y t o servovalves, l a p i s defined as the

t o t a l separation a t zero f l o w o f s t r a i g h t 1i n e extensions o f the
s t r a i g h t portions o f the normal f l o w curve f o r each p o l a r i t y .

Figure 10

i l l u s t r a t e s t h i s d e f i n i t i o n , showing the conditions o f zero lap, underlap, and overlap.

It w i l l be shown t h a t servovalve performance i s

g r e a t l y affected by the l a p conditions.

The dynamic response o f a valve i s usually characterized by i t s
frequency response t o s i nusoidal i n p u t currents.

Frequency response i s

described by means o f a Bode p l o t , which shows the e f f e c t o f frequency

on phase angle and amplitude r a t i o .

Spool lands wider

than bushing slots

Control #1

7 h r,

Control

Fig 8.

Return

Over1apped Spool

Bushing slots wider

than spool lands
Cont

Fig. 9.

Underlapped Spool

/-I
Zero Lap

Normal Flow
Curve

7
A

Underl ap
Region
Underl ap

Fig. 10.

Lap Defined f n

Terms o f Flow Curve

-over1

ap
Region

CHAPTER V
SYSTEM REQUIREMENTS AFFECTED BY A SERVOVALVE

A generalized explanation of a position servo and the function of a

servovalve in a position servo was presented in chapter 111. This simpl ified description appl ies to a1 1 types of electrohydraulic position

servos, a1 though systems may vary greatly in complexity, expense, size,

etc.
Due to the exacting tasks which must be performed, the specification for a missile control system is an exceedingly complex document,
with every aspect of performance, environment, reliability, etc., specif ied. Re1 ating every system characteristic with the many servoval ve
characteristics would be a task beyond the scope of this report. In
fact, many interrelationships would not be significant. But in a missile control system, as in the simplest control system, the key problems
of the designer can be addressed by considering the more important system requi rements which are i nf 1uenced by or i nf 1 uence servoval ve performance requirements. Performance requirements to be considered are
positioning accuracy, dynamic response and stabi 1 i ty, energy consumption, and rate capability. Other important system requirements which
will be considered are tho following:
1,

Thermal environments

2.

Dynamic environments

3.'

Cost

shock, vibration, acceleration

4.

Life

5.

Physical constraints

6.

Fluid cantamfnatlon level

- weight,

size

The interrelationships o f the above system requirements and servovalve

parameters wi 11 be discussed tn the foll owing chapters.

CHAPTER VI
INTERRELATIONSHIP OF SYSTEM REQUIREMENTS AND SERVOVALVE PARAMETERS
Since one of the prime reasons for using an electrohydraul ic position servo is its ability to position a load accurately, it follows that
posi tioning accuracy is an important characteristic to be considered.
which effect positioning accuracy are nu1 1 flow
gain, hysteresis, nu1 1 bias, threshold, and pressure gain.
In a positlon servo, most of the operating time of a valve is
around the null position, as it is continually working to drive the
error signal to zero. Hence, null flow gain (as distinguished from
normal flow gain) will affect positioning accuracy. A valve with underlap has a high flow gain around null. This is desirable from the standpoint of reducing its positioning error: However, any disturbance of
the output stage, due to shock, vibration or acceleration, or electromagnetic disturbance of the first stage torque motor or noise on the
comnand input, wi 1 1 cause a relatively large increase in flow to the
actuator. This flow increase will result in a rapid position shift
which will be corrected by the position feedback, but the net result
will be a tendency for the system to oscillate from a commanded position
when exposed to an external disturbance. A further problem is that
valves tend to exhibit a null shift due to age, contamination, and thermal and dynamic environments. The effect of null shift on a valve with

fl

high null-flow gain is to increase a system's tendency to oscillate

about its commanded position.

An overlapped valve has a lower flow gain in the null region, as

~----

shown in figure 10. This appear

of deadzone is to increase
.**eht

s deadzo

to a system. The effect

From a standpoint of positioning accuracy, a zero lap valve with

1 inear flow gain throughout the null and normal flow regions i s the

ideal situation. In fact, most servovalves are considered to be as

close to zero lap as possible, with minimum overlap.16

In this way, a

moderately high gain minimizes error, but the valve is not as sensitive
to external disturbances as with an underlapped valve.
Another s e r v o v d a K t 3 which decreases positioning accuracy
d
'

is hyHxrerfs.

steresis is affected by temperature, fluid

contamination, and electromagnetic effects. At -30F, for example,

hysteresis increases by 25% over room temperature 1 eve1 s.

~ontamina-

tion, which increases internal friction also increases hysteresis.

Finally, magnetic effects, such as external magnetic influences or installation on a magnetic manifold, can increase valve hysteresis and
systern posit i on error.
As stated earl ier, practical ly a1 1 servoval ves exhibit nu1 1 bias.
'--\

y introduce
_ -,---.- system err , as an error signal will
be required to null out the valve. Null bias is affected by supply
1 w

.+
L
I-

--^

pressure fluctuations. This may be significant in systems which use oil

over gas accumulators to meet short high demand situations or in systems
with a great deal of pump ripple. Temperature variations can effect
null bias, due to fluid effects

the f irstr stage torque motor.

mechanical shock and even age.

Nu1 1 bias a1so tends to change w i t h

(9
can also occur due to second stage effects,
3.--

,'-)

In h i g h acceleration environments@

' i,s mass-balanced about

;.

since the f i r s t stage

i t s pivot. l8 Typical values for an aerospace

19

valve are 20.2% rated current per 6.

Thresh01d i n a servovalve contributes to increased system posi t i on

error. Threshold is affected by fluid contamination level, supply
pressure, temperature, and output spool lap. The effect of fluid contamination on valve threshold can be significant. This i s one of the
main reasons for maintaining a clean hydraulic system. Because of the
t i g h t spool/bushing diametrical clearances on a servovalve, as shown i n

table 1, the presence of small particles will tend to cause spool friction, and hence threshold, to increase.

The effect of fluid contamina-

tion level on threshold i s shown in figure 11

.'* Table

3 presents a

classification scheme for system clean1iness developed by the SAE.

In a two-stage valve, threshold depends on the force available
to drive the second stage spool. Therefore, supply pressure will affect
threshold.

The spool driving force i s dependent on the pressure avail-

able on the ends of the spool. Any significant decrease in supply pressure w i 11 increase valve thresh01d.

-L------

sxhj_bi

_ .&.

1,-

--_,

,* *.

-*"\,

significant changes
in viscosity/,

b~

. The increased viscooi ty a t low tempL

9s
eratures results in large increases i n threshold. In fact, for a typi/-

o er extreme temperature ra
--"-

cal valve, threshold doubles a t -30F from i t s room temperature value. 21

Spool lap can also have an influence on the threshold of a valve.
I t has been shown that fluid contamination level increases threshold by

.I.

Upper L i m i t of
Observed Thresh01 d

.
P

..

-.01

.02

..

Fig. 11

-0-

.05

0.1

0.2

0.5

Contamin a t i on Level in M i 11igrams per 100 Mi 11i1iters

E f f e c t o f Fluid Contamination Level on Servovalve Threshold,

TABLE 3
CLEANLINESS CLASSIFICATION BY NUMBER OF PARTICLES
IN 100 MILLILITER FLUID SAMPLE
Size Range i n Microns
Cleanliness Class

5-10

10-25

25-50

50-100

100 Plus

increasing spool f r i c t i o n .

I n the presence o f f l u i d contamination, a

valve spool a t n u l l has a tendency t o s i l t , t h a t i s , t o b u i l d up a wall

An over-

o f contamination between

lapped valve, because o f the small leakage paths involved, has a greater
susceptibility t o silting.

Hence, an underlapped valve, by v i r t u e o f

the l a r g e r leakage paths and r e s u l t i n g constant flow through the meteri n g edges has l e s s o f a tendency t o s i l t .

This i s desirable i n avoiding

threshold increase w i t h f l u i d contamination.

One method o f improving servoval ve threshold without changing the
/---

valve i s t o ad
high frequency

.,

- - - z-.--,&-'-;;:;:;.-:

&-+,

i s a low
-.
amp1 i t u d -eDither ._I-_

t o the i n p u t signal.
,4

-C

on the input.

,>-I

r&*y-+
--

&;-,&Lm.%.7.

, . .

The e f f e c t o f d i t h e r

i s t o cause low amplitude high frequency motion o f the output spool.

As

Gee4ic.
.
4

a resul t, apparent spool f r i c t i o n i s decreased

.-

- --

-#

-+-------\

t i o x slldi*
s f 1t i n g from occurring.

Further, the motion o f the spool prevents

The d i t h e r frequency should be high enough i n

frequency and low enough i n amplitude t h a t no measurable system response

i s caused.

For example, the recomnended frequency range f o r a d i t h e r

signal is from 100 t o 400 hertz, and the recomnended ampl itude i s up t o
20% o f r a t e d current.22

The e f f e c t o f such a d i t h e r signal on a second

order system having a bandwidth o f 60 hertz i s shown i n f i g u r e 12.

At

frequencies o f 100 hertz and higher, system response has dropped o f f so

much t h a t no measurable system output i s produced.

D i t h e r frequency

should not exceed 400 hertz t o insure t h a t movement o f the valve output
spool occurs.
When a hydraulic system i s c a l l e d upon t o p o s i t i o n a load,

tend t o a l J s i t i o n .

Due t o the

4
I

36

of the fluid column i n the actuator, a valve w i t h high

pressu e gain can cause t h e system t o respond rapidly t o such toad

disturbances and hence improves positioning accw
or other load disturbances. For a gSven valve,
contamination level, age and spool lap. The effect of

with

temperature on pressure gain can be seen from an analytical expression

f o r pressure gain about null of a spool valve: 23

where
$0

n u l l pressure gain

1.1

= fluid viscosity

Cd

Ps

= supply pressure

discharge coefficient

)"c = radial clearance

Cl early, since f l u i d viscosity and densi

----

will press&% gain.

.-.--.....
va6~wi
.
th

tempwture-, so

I
-

For a Moog series 30 valve, vendor data indicate

valve pressure gain may be reduced 25% a t -30F.

High levels o f f l u i d contamination are harmful to the pressure gain

of a servovalve. Operation of a servovalve w i t h contaminated fluid will

result in a large amount of erosion and wear over a period of time.
Metering edges of the spool and sleeve wi 11 become rounded, resul t i n g in
a decrease i n pressure gain.
The effect of spool lap on pressure gain i s shown i n figure 13. As
can be seen, pressure gain i s higher for a sl ightly overlapped and zero

p:2,:-

- -.

.. r - - -.a-

. .r

- 8 .

-.

-.hA-

. ,

..

-.

--

. . *-.. ' .

-/.

.
. .._,, . . . .
. ..- . . . :.,; ...
.LC'- ., &
'

l a p valve than an underlapped valve.

Pressure gain i s lower f o r an

underlapped valve since the underlap produces an intermediate pressure

t o the c y l i n d e r ports a t n u l l .

F u l l system pressure i s not developed i n

a control p o r t u n t i l the leakage path t o r e t u r n i s blocked---.

qu-longer

stroke than i n an overlapped o

*
- - -

though an overlapped valve e x h i b i t s a pressure gain as high as a zerol a p valve once the deadzone i s traversed, the l a c k o f deadzone makes a
zero-lap the i d e a l condition f o r maximum gain.24

Due t o d i f f i c u l t i e s

involved i n producing a zero-lap valve, the best p r a c t t c a l condition f o r

i s a minimum overlap servovalve.

pressure gain
o f a system, another key system

Besides
performance concern i
element o f a system, t

e.

As an important dynamic

f e c t o f servoval ve parameters on frequency

response should be investigated.

The parameters a f f e c t i n g frequency

response are. f l o w gain, threshold, f i r s t stage flow, pressure gain, and

dither.
The value o f flow gain a t n u l l i s an important c r i t e r i o n i n determining frequency response and s t a b i l i t y o f a system.

This can be i l l u s -

t r a t e d by examining the block diagram o f a simple p o s i t i o n servo, as

shown i n f i g u r e 14.

I n t h i s example, i t i s assumed t h a t a m p l i f i e r and

feedback dynamics can be neglected, compared t o the servoval ve dynamics

Further, u n i t y feedback i s assumed.

The servovalve dynamics can be

represented by a second-order t r a n s f e r function.

the s t a t i c f l o w gain o f the servovalve.
system i s

The quantity K i s
q
The open-loop gain o f t h i s

where
K o ~ = system open loop gain
Ka

Kq
A

= a m p l i f i e r gain
=

servovalve f l o w gain

actuator area

I t can be seen t h a t the open loop gain can be increased by i n -

creasing servovalve f l o w gain.

Increasing open loop gain r e s u l t s i n

b e t t e r post t i o n i n g accuracy and b e t t e r dynamic response, i f stab11it y i s

n o t a problem.

However, care must be taken t h a t the valve f l o w gain i s

n o t so high t h a t i n s t a b i l i t y results.
l a r g e can be seen i n f i g u r e 15, a root..-

l a c p~ l ~o ~ Y Y s t m - o f fi g u r e 14.

I n order t o have a stable sys-

tem, a l l r o o t s o f the c h a r a c t e r i s t i c equation o f the system must be i n

the l e f t h a l f o f the S-plane.

For the system being discussed, f o r a

value o f open loop gain greater than Km, two o f the roots o f the charact e r i s t i c equation w i l l l i e i n the r i g h t h a l f o f the S-plane, and the
system becomes unstable.

Therefore, a system s t a b i l i t y should be con-

sidered when determining the f l o w gain o f a servovalve.

For a spool valve a t nu11, the expression f o r f l o w gain i s : 25

where
Kso

'

n u l l f l o w gain

Cd

= discharge c o e f f i c i e n t

peripheral width o f the spool s l o t s

Ps

supply pressure

= mass density

Fig. 15.

Root-Locus Plot f a r System o f Fig. 14

42

Clearly,. the flow g;in is influenced by the configuration of the spool

slots, and by fluid properties.

If flow gain must be adjusted, these

parameters, as well as spool lap conditions, must be considered. A

further cmpl ication around null is the magnitude of another important
valve parameter, Kc, the flow-pressure coefficient. Where flow gain
affects the open loop gain of a system, Kc contributes to the damping
coefficient of a

At null, K O is a minumum. The theoretical

value for Kco is zero, and for a practical ~alve:~'

where
null flowpressure coefficient

Kc*

= peripheral width of spool slots

= radi a 1 c1earance

= fluid viscosity

Plugging in .typical values for a Moog Series 30 valve Q 3000 psi,

In the case of an under-lapped valve, the situation at null i s critical

in determining a system's stability and frequency response. Here, the
7

damping is a m i n i m due to the low value for KCo. If a system is

m
stable when operated about null, it will in general be stable every.".)*.sUI+_

where.

If stability at null is a problem, the null flow gain must be

reduced. This may be accomplished by reducing the underlap (if the

valve i s underlapped) or by modifying the shape of th($-iiervovalvesleeve--.'---As
was shown in equation
the flow gain of a servovalve is
dependent on w, the peripheral width of .the spool slot.
VI.3,

FOP operation o f f n u l l , the above comments apply i n a s i m i l a r

fashion t o t h e normal f l o w gain.

Another valve parameter whi ch a f f e c t s frequency response i s threshold.

The e f f e c t o f increased threshold i n a valve i s t o decrease low

amp1itude frequency response and possibly cause i n s t a b i 1ity.28 Degrad a t i o n o f frequency response due t o threshold can be e l ilninated by
introducing d i t h e r .

Since threshold i s a f f e c t e d by contamination, i t i s

apparent t h a t h i g h 1evels o f f l u i d contamination can cause frequency response and s t a b i 1ity problems.
Dynamic response under load can be improved by increasing the
pressure gain o f a servovalve.
load.

This a1 lows f a s t e r acceleration o f a

I n addition, a high pressure gain increases

wn

o f a system, which

may provide a wider frequency range w i t h o u t encounteri ng resonances.

Another item which a f f e c t s frequency response i s f i r s t stage hyd r a u l i c a m p l i f i e r flow.
quency response. 29

Increasing f i r s t stage f l o w w i l l improve f r e -

I n a d d i t i o n t o the e f f e c t s discussed above, environmental i n fluences on a servovalve can a f f e c t system performance.

extremes can degrade threshold and hence system response.
sustained acceleration.

Temperature
So, too, can

Other dynamic environments which may a f f e c t

sys tern performance by a1t e r i ng servoval ve parameters are shock and

vibration.
Energy consumption i s another system c h a r a c t e r i s t i c which can be
influenced by the design o f a servovalve, s p e c i f i c a l l y , i t s leakage
flow.

In many systems, t h i s can be o f l i t t l e o r no importance, as i n

f i x e d i n s t a l l a t i o n s w i t h ample power supplies.

However, i n other

systems; such as mi ssi 1es, weight and size constraints may severely
limit the amount of energy available to operate a system. Further, in
many such systems, such as missiles, most of the system activity i s a t a
low (trim) level for a majority of the time, so that leakage may dissipate the b u l k of the energy.

In cases like this, the impact of a servo-

valve on system energy consumption must be addressed.

Internal 1eakage

of a servoval ve i s affected by temperature, machi ni ng to1 erances contamination levels, and lap conditions.
Temperature extremes can affect leakage flow due t o changes in
fluid properties.

W i t h increasing temperatures, the decreased viscosity

of hydraulic fluid results i n increased leakage.

Depending on the spool

and sl eeve coefficients of thermal expansion, h i g h temperatures can

increase or decrease 1ea kage due to expansion. Since clearances affect
leakage flow, leakage can be decreased by machining the valve spool and
sleeve to tighter tolerances, and reducing the diameter of f i r s t stage
nozzles.

Contamination level may adversely affect 1eakage since 1eakage

increases w i t h age due to erosion caused by high contamination levels.

As has been explained previously, lap conditions can strongly affect

leakage flow.

The more underlap a valve has, the greater the leakage.

I---

Since the effect o@

- Jn

--~7

tion of dither t o a system can incre~,servovalve leakage flow.

--------\A<

'.,.---I-----

One other system characteristic inf 1uenced by servoval ve parameters

i s i t s rate capability, which in t u r n is determined by the flow rating
of a servoval ve.

Typical f low-load characteri stics for a servoval ve are

shown i n figure 16. 30 I t can be seen that the flow-load curve i s a

square root relationship for a given i n p u t current.

The flow rating for

r
Ir

100% Rated Current

80% Rated Current

'rent

Current

20
40
60
80
100
Load Pressure Drop, % o f Supply
'

Fig. 16. Typical Flow-Load Characteristfcs

46

a servmlve vs. supply pressure also conforms to a square root re1ationship.

In systems w i t h accumulators which experience a dropoff i n

supply pressure w i t h Increasing demand, the rate capabil ity may be reduced. As can be seen from figure 1

atso reduces the

control flow from a servovalve. Therefore, when sizing a servovalve for

a system, care must be taken in considering the compatibility of load

and supply pressure wfth rate requirements.

CHAPTER V I I
EXAMPLES OF SYSTEM REQUIREMENTS PRIORITIES
While any electrohydraulic p o s i t i o n i n g servo can be conceptually
explained by the explanation i n Chapter 111, the type o f a p p l i c a t i o n o f
the servo can influence the order o f p r i o r i t y o f requirements.

In

sel ecting a servovalve, those p r i o r i t i e s can determine the characteri s t i c s required i n the selection o f a servovalve.
requi r m e n t s

The v a r i e t y o f

can be i11ustrated by discussing some general systems.

The t y p i c a l m i s s i l e control system i s a high response, high e f f i ciency system.

Frequency response and posi t i o n i n g accuracy are im-

portant i n rnlssile application.

Since weight and s i z e are t i g h t l y

constrained, the amount o f energy available t o power the system i s

1i m i ted.

Lirni ted energy avai 1abi 1it y , coup1ed w i t h missions which have

long periods o f low f t n a c t i v i t y , i n d i c a t e t h a t a low leakage servovalve

i s a high p r i o r 1ty.

Dynamlc environments, p a r t i c u l a r l y shock and accel-

eration, are extremely high, and a servovalve must e x h i b i t resistance t o

n u l l s h i f t s from such effects.

Thermal environments are also severe,

w i t h operating ranges over several hundreds o f degrees.

The servovalve

must be designed t o minimize the impact o f these extremes.

Because o f

the r a p i d deployment o f a missile, start-up time f o r a m i s s i l e i s short,

w i t h only seconds f o r the system t o activate.
Other servovalve requirements have less importance.

Since the

mission time o f missiles i s short, being measured i n seconds o r minutes,

servova-hre l i f e i s n o t a serious concern.

Because o f the short l i f e and

t h e f a c t t h a t m i s s i l e s have clean, sealed hydraulic systems, the contamination s u s c e p t i b i l i t y o f a servovalve i s n o t a problem.

Finally,

because o f the severe dynamic, thermal, and performance requirements,

cost i s n o t t h e o v e r r i d i n g concern i t may be i n other applications.
A i r c r a f t c o n t r o l systems have d i f f e r e n t p r i o r i t i e s than missiles.
Here, u n l i k e "one-shot" missiles, mission times are long, and l i f e
requirements are s p e c i f i e d i n thousands o f hours.
an important servoval ve requirement

Hence, long 1i f e i s

Because o f the 1ong duration

missions, the a b i l i t y o f a servovalve t o be r e l a t i v e l y unaffected by

temperatureltime conditions i s important.

As on missiles, weight and

s i z e a r e important constraints, and f o r t h a t reason, most a i r c r a f t

systems operate a t 3000 p s i and higherO3' The thermal and dynamic
environments are severe, a1 though n o t as severe as i n missiles.

Gener-

a l l y , the energy a v a i l a b l e f o r an a i r c r a f t system i s n o t as l i m i t e d as

i n a missile, so low servovalve leakage i s n o t a major concern i n a i r c r a f t appl ications.

Accuracy and frequency response are n o t as s t r i n -

gent as m i s s i l e requirements, although s t a b i l i t y under load i s important

i n withstanding f l u t t e r loads.

Again, because o f the complexity o f

a i r c r a f t , and because o f human safety requirements, c o s t i s n o t a major

c o n s t r a i n t i n servovalve selection.
I n d u s t r i a l systems, such as i n numerical c o n t r o l appl ications, have
d i f f e r e n t p r i o r i t i e s than a i r c r a f t o r m i s s i l e systems.

Here, p o s i t i o n -

i n g accuracy and s t a b i l i t y under heavy loading are important, more so

t h a n frequency response.
inches a r e n o t uncommon.32

For instance, p o s i t i o n i n g accuracies o f 0.005

Long component 1i f e i s important t o minimize

1
I

rnaintenu~ceand down time. Since such systems operate in dirty

environments, with vented hydraul ic systems, servoval ves for such
appl icati ons should have a high contamination to1 erance. Compared to
missiles and aircraft, cost is a more significant consideration in
servovalve selection. Industria1 systems have access to re1 atively
limitless energy supplies, so servovalve leakage is not a problem.

In

general, the dynamic environments are not severe, which can affect valve
configuration. Since an industrial system often operates in a controlled environment, such a system does not see a wide range of temperature extremes.

The effect of appl ication of a servovalve on performance requirements is quantitatively illustrated in table 4. Representative data for
typical aissi 1e, aircraft, and industrial requirements are sumnari zed.
These data show the variation in performance requirements with intended
use as discussed in the preceding paragraphs.
As should be evident from the preceding discussion, the appl ication

of a position servo will determine the priorities in selecting a servovalve. Systems requirements have been presented in general terms only,
and there are many systems which do not correspond to the above description. However, the intent was merely to illustrate the ordering of
priorities that a designer may face. In recognizing that these priorities exist, the designer can then specify a servovalve whose performance
characteristics best fit system requirements.

TABLE 4

REPRESENTATIVE SERVOVALVE PARAMETERS

FOR VARIOUS APPLICATIONS
Missf les

Ai rcraft

Industrial

Rated flow, QR

3.35 gpm

0.30 gpm

2.5 gpm

Leakage flow, QL

0.14gpm

<0.22gpm

~0.35 gpm

60 hrs

5000 hrs

Class 2

Class 3-4

QL'QR

Bandwidth
Operating 1 i fe
System clean1 iness level*

Class 5-6

* See Table 3 for definition of cleanliness levels

** Because manufacturer has no control over contamination levels,

no operating life guarantees are made for industrial valves.

valves are warrantied for one year against any defects.

Instead,

CHAPTER VIII
GENERAL GUIDELINES AND CONCLUSIONS
It has been the intent of this report to illustrate the effect of
system requirements on servovalve configuration. As shown in the preceding chapter, the application of a servo system can result in a variety of priorities.

In determining the characteristics of a servoval ve, the designer

must make intellfgent choices. The first consideration is to make sure
the servovalve requirements are realistic. Overspecifying a performance
characteristic will unnecessarily increase component cost, and may
adverse1y effect other important valve characteristics.
A source of problems in writing specifications for servovalves is
to be unreal istic in specifying performance of a servovalve over its
entire life span and under all environmental conditions. Expecting a
valve to perform to the same level at the end of life as when new is
unrealistic, costly, and often not necessary. Regardless of excellence
of design, it should be recogni zed that certain conditions experienced
over the 1 ife of a servovalve will degrade performance, especially fluid
contamination, el ectrical overl oads , and pressure overl oads.

For ex-

ample, over the life of a valve, high fluid contamination levels will
increase leakage flow, degrade linearity in the null region, decrease
pressure gain, and increase hysteresis and threshold. Similarly, it is
unrealistic, regardless of design, to expect no change in servovalve

p e r f o m c e over a wide range o f thermal and dynamic environments.

For

example, below -20F using MIL-H-5606 hydraulic f l u i d , only l i m i t e d

performance w i 11 be obtafned. j3 Parameters most 1ik e l y t o be affected
by thermal o r dynamic anv$ronments include n u l l bias, r a t e d flow, leakage flow, threshold, hysteresis, and l i n e a r i t y .
Oftentimes, othar c h a r a c t e r i s t i c s o f a system change as we1 1, and
the impact o f the servovalve can be minimal.

For example, i n the con-

t r o l section o f some missiles, leakage flow o f the servovalve a t high

temperatures i s s i g n i f i c a n t l y above the flow a t the low temperature
extreme.

This creates a greater energy demand f o r a high temperature

mission.

However, a t the same time, the energy del i v e r y o f the con-

t r o l section power supply can improve a t h i gher operating temperatures.

The r e s u l t i s t h a t the n e t impact o f temperature on energy require-

ments/capaci t y i s minimfzed.
applications.

Similar sf tuations c m occur i n other

A t the very least, the designer should explore system

requirements before imposing unreal i s t i c 1i m i t s on performance a t dynamic and thermal extremes.

I n speci f i y i n g servoval ve characteri s t i c s , the designer should be
aware o f the tradeof f s invol ved.

Mobt importantly, specifying 1ap

condition, leakage flow, i n p u t signal c h a r a c t e r i s t i c ( d i t h e r ) , and system contamination 1eve1s a11 invol ve important tradeof f s

Overlap i n a valve improves valve 1 i f e due t o lower erosion wear,

and reduces energy demand by reducing valve n u l l lealgge.

Moderate

amounts o f overlap also r e s u l t s i n h,igher pressure gain than i n an

underlapped valve, which improves frequency response and stabi 1it y due
t o 1oad f 1uctuati ons.

Over1ap, however, can increase p o s i t i o n i ng e r r o r

53
by intmducing deadzone.

Contamination suscepti b i 1it y o f a valve i s

increased i n an overlapped valve.

Contamlnati~ni s 1i k o l y t o cause

s i 1ting, which i n turn can cause system i n s t a b i 1ity.

Underlap, on the other hand, improves dynamic response a t small
amp1itudes and decreases the contamination sensi ti v i ty o f a val ve.

By

allowing leakage paths t o be c o n t i n u a l l y flushed w i t h f l u i d , r a t e

c a p a b i l i t y degradation due t o blockage o f f l u i d passages w i t h time i s
avoided.

Unfo r t u n a t l ey , the e f f e c t o f under1ap i s t o inorease 1eakage

flow, which i s undesirable when the energy supply i s l i m i t e d .

tion, system performance f o r l a r g e amplitudes i s degraded.

I n addi-

For stabi-

1i t y , system gain must be s e t a t nu11, where the valve c o n t r i b u t i o n t o

damping i s low and the f l o w gain i s highest.

As a r e s u l t , system gain

decreases a t 1arga input, and p e r fomnee r u f fers

Leakage f l o w i n a valve i s another parameter c o n t r o l l e d by the

design.

From the standpoint o f frequency response and contami nation

s u ~ c e p t i b i l l t yhigh
~
leakage i s desirable.

Because high leakage may

allow looser clearances, cost m y be favorably impacted.

However, the

disadvantages f rorn a high 1eakage a11wance i n c l ude reduced 1i f e and

performance degradation due t o erosion wear, reduced pressure gain, and
increased energy consumpti on.
I n p u t s,ignal c h a r a c t e r i s t i c s
and system performance.

ti.@., d i t h e r )

can also a f f e c t valve

Dither, by reducing apparent thresh01 d and

over1ap, improves p o s i t i o n i n g accuracy, frequency response, and stabi

lity.

The tendency f o r s i l t i n g t o occur i s raduced, so contamination

s e n s i t i v i t y i s decreased.

However, energy considerations may preclude

the i n t r o d u c t i o n o f d i t h e r i n t o a-system.

The preceding discussion i 11 ustrates the tradeoffs which must be

made in specifying a servovalve for a given application. No hard and

fast rules can be made.

Specification of valve performance must be made

on the basis o f syrt& requirements. With some knowledge ~f the interrelationships which exist, the designer can specify the most suitable
valve for a given application.

FOOTNOTES

(East Aurora, N.Y. : Moog, Inc.,

rs, Inc., E l ectrehydraul i c Flow-

New Yerk:

Society o f Automotive Engi-

, 2nd

ad. (Cleveland:

1nQug

Engineers, Inc., Electrohydraulic Flow-

1.

W d ~ a uilc Contrcrl Systems (New York:

pe 42.

John

'~arnes E. .Johnson, Electrohydraul i c Servo Systems (Cl eve1and:

Industrial Pub1 ishing Company, 1973), p. 42.
l 0 ~ o c i e t yof Automotive Engineers, Inc. , El ectrehydraul i c Flow-

Control Servovr 1vesh, p. 12.

'yeapl e, Hydraul i c and Pneumatic Power and Control , pp. 206-207.

2 ~ o c i e t yof Automotive Engineers, Inc., Electrohydraul i c Flow-

Control Sarvovr.lves, p. 12.

1 3 ~ r rtt,
i Hyd-rauli c Control Systems, pa 78.
141bid.

- -.1.6~ocioty--of
-Automotive Engineers, Inc.
Control ScrvovaSves, p. 13.'
.

'

, Elactr~hydrau.1i c Flow-

7J&pe 30 Flw Control Servoval vos, p. 12.

'OL. Jack Willtms, f l u i d Contagtination Effects on Servovalve Performance (East A u n ( ~ b,*Yo: Moog E.,
1967), p. 5.

2 1 ~ y p e30 Flaw Csrttrol Servovalves, p. 12.

bid., p.

8.

23~erritt, Hydraul i c Control Systems, p. 91 .

24~eller, Hydraulic System Analysi S , p. 109.
25~errltt, Hydraulic Control Systems, p. 87.
26~bid., p. 84.

bid., p.

91.

28~ociety o f Automotive Engineers, Inc., Electrohydraulic FlowControl Servovalves , p. 1 2.

29~ype30 Flow Control Servovalves, p

3%erritt,

Hydraulic Control Systems,

31~bid., pp. 224-226.

32~ational Conference on Industria1 Hydraul ics , Proceedings of
the Nineteenth Annual Meeting (Chicago: n. p. , 1963), p. 93.
'%ociety
of Automotive Engineers, Inc., Electrohydraulic FlowControl Servovalv-,, p. 15.

SELECTED BIBLIOGRAPHY
Clark, Danlal C.

pis, Constantine H. Feedback Control System

sis. New York: McGrrw-Hi11 Book Company,
Electrohydrwlic Flow-Control Servovalves.
Automotive Engfneers, Inc. , 1970.

New York:

Johnson, juaes E. Electrohydraul i c Servo Systems.

Industrial Publishing Company, 1973.

Kel 1er, George R.

Hydraulic System Analysis.

Industrial Publishing Company, 1974.

Merritt, Herbert E.

Hydraulic Control Systems.

Wiley & Sons, Inc., 1967.

Society of

Cleveland:

2nd ed.

Cl eve1and :

New York:

John

National Conferance on Industri a1 Hydraul ics. Proceedings of the

Nineteenth A~nualMeeting. Chicago: n. p., 1963.
Neal, T. P.
systems.
Roess, L. G o Control Contamination i n Hydraulic Systems.
East Aurora, New York: Moog, Inc., 1970.

TB 114.

Thayer, Will iam J. Specification Standards for Electrohydraul i c

Fl ow Control Servoval ves TB 117. East Aurora, New York:
Moog, Inc., 1962.

'

Sun,- 1 Pressure Considerotions f o r Servoactuators

EasHurora, ~ e wYork: bog. Inc., 1967.
-

Transfar Functions f o r Moog Servoval ves.

East Aurora, New Ydrk: Moog, Inc., 1965.
Type 30 Flow Contrel Servovrlves.

1974.

TB

TB 103.

East Aurora, New York:

Moog, Inc.

WieberieRobert H . , and Schmidt, Henry A. Time-Optimal El ectrohydraulic Servo Positioning System for Replaceable Disk Memory
Units. TB 123. -fast Aurora, New York: Moog, Inc., 1970.
Williams, L. Jack. Fluid Contamination Effects on Servovalve Performance. TB
East Aurora, New York: Moog, Inc., 1967.

1n.