1 Hydraulic Systems Volume 2: Electro-Hydraulic Components and Systems

Table of Contents

Hydraulic Systems Volume 2

Electro-Hydraulic Components and Systems

Lecture # 001-Wednesday- July -31-2024

PREFACE, 10
ACKNOWLEDGEMENT, 11
ABOUT THE BOOK, 12
ABOUT THE AUTHOR, 15
Chapter 1: Hydraulic versus Electrical Systems, 16
1.1- Structural Analogy between Hydraulic and Electrical Systems, 17
1.1.1- Power Generation (Conversion), 18
1.1.1.1- Electrical Power Generators, 18
1.1.1.2- Hydraulic Power Generators, 19
1.1.2- Power Control, 20
1.1.2.1- Power Quantification, 20
1.1.2.2- Effort Variable Controllers (Overload Protection), 21
1.1.2.3- Flow Variable Controllers (Resistive Elements), 22
1.1.2.4- Directional Controllers, 28
1.1.2.5- Energy Storage Elements (Capacitive Elements), 29
1.1.2.6- Non-Return Elements, 30
1.1.2.7- Electrical versus Hydraulic Power Control Elements, 30
1.1.3- Power Consumption (Actuation), 31
1.1.3.1- Rotational Actuators, 31
1.1.3.2- Linear Actuators, 33
Lecture # 02-Wednesday- August -07-2024
1.2- Operational Analogy between Hydraulic and Electrical Systems, 34
1.2.1- Energy Transmission in a Circuit, 34
1.2.2- Energy Transmission Efficiency, 35
1.2.3- Energy Transmission Cost Factor, 36
1.2.4- Energy Transmission Distance, 37
1.2.5- Readiness of Operation, 38
1.2.6- Cleanliness of Operation, 39
1.2.7- Maintenance of Operation, 40
1.2.8- Safety of Operation under High Temperature, 41
1.2.9- Noise of Operation, 42
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Chapter 2: Hydro-Mechanical versus Electro-Hydraulic Solutions, 43

2.1- Features and Challenges of Electro-Hydraulic Systems, 44
2.2- Pressure Control Solutions, 46
2.2.1- Pressure Control using Hydro-Mechanical Pressure Relief Valve, 46
2.2.2- Pressure Control using Hydro-Mechanical Pressure Compensated Pump, 47
2.2.3- Multiple Pressure Settings using Electro-Hydraulic Switching Valves, 48
2.2.4- Pressure Control using an Electro-Hydraulic Continuous Valve, 50
2.2.5- Pressure Control using an Electro-Hydraulic Pressure Compensated Pump, 52
Lecture # 03-Wednesday- August -14-2024
2.3- Flow Control Solutions, 54
2.3.1- Flow Control using Hydro-Mechanical Flow Control Valve, 54
2.3.2- Flow Control using Hydro-Mechanical Displacement Controlled Pump, 55
2.3.3- Multiple Flow Settings using Electro-Hydraulic Switching Valves, 56
2.3.4- Flow Control using an Electro-Hydraulic Continuous Valve, 58
2.3.5- Flow Control using an Electro-Hydraulic Displacement Controlled Pump, 60
2.3.6- Flow Control using a Fixed Pump Driven by Variable Speed Motor, 62

2.4- Power Control Solutions, 64

2.4.1- Hydro-Mechanical Power Controlled Pumps, 65
2.4.2- Electro-Hydraulic Power Controlled Pumps, 67
Lecture # 04-Wednesday- August -21-2024
2.5- Sequence Control Solutions, 70
2.5.1- Hydro-Mechanical Sequence Control, 70
2.5.2- Electro-Hydraulic Sequence Control, 71

2.6- Hydraulic Deceleration System, 73

2.6.1- Hydro-Mechanical Deceleration System, 73
2.6.2- Electro-Hydraulic Deceleration System, 74

2.7- Cylinder Speed Synchronization, 75

2.7.1- Hydro-Mechanical Cylinder Speed Synchronization, 75
2.7.2- Electro-Hydraulic Cylinder Speed Synchronization, 76
Lecture # 05-Wednesday- August -28-2024
2.8- Accumulator Charging, 77
2.8.1- Hydro-Mechanical Accumulator Charging, 77
2.8.2- Electro-Hydraulic Accumulator Charging, 78

2.9- Control of Overrunning Loads, 80

2.9.1- Hydro-Mechanical Overrunning Load Control, 80
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2.9.2- Electro-Hydraulic Overrunning Load Control, 81

2.10- Control Block Actuation in Mobile Applications, 82
2.10.1- Hydro-Mechanical Control Block Actuation, 82
2.10.2- Electro-Hydraulic Control Block Actuation, 83

Chapter 3: Switching Valves Construction and Operation, 84

3.1- Basic Electro-Magnetic Concepts, 85
3.1.1- Magnetic Field around a Conducting Wire, 85
3.1.2- Magnetic Field Measuring Units, 85
3.1.3- Magnetic Field Intensity, 86
3.1.4- Magnetic Field around a Coil, 87
3.1.5- Electro-Magnetic Force, 88
Next Lecture – To be Defined Later
3.2- Switching Solenoids, 89
3.2.1- Switching Solenoid Basic Structure, Operation, and Functions, 89
3.2.2- Wiring Methods of a Coil, 92
3.2.3- Switching Solenoids Force-Stroke Relationship, 95
3.2.4- Switching Solenoid Performance Terminologies, 97

3.3- Switching Solenoids for Electro-Hydraulic Valves, 99

3.3.1- Dry (Air) Type Switching Solenoids for EH Valves, 99
3.3.2- Wet (Oil) Type Switching Solenoids for EH Valves, 101
3.3.3- Dry versus Wet Type Switching Solenoids for EH Valves, 102
3.3.4- DC Switching Solenoids for EH Valves, 103
3.3.4.1- Construction and Operation of DC Switching Solenoids for EH Valves, 103
3.3.4.2- Performance of DC Switching Solenoids for EH Valves, 104
3.3.4.3- Applications of DC Switching solenoids for EH Valves, 105
3.3.5- AC Switching Solenoids for EH Valves, 106
3.3.5.1- Construction and Operation of AC Switching Solenoids for EH Valves, 106
3.3.5.2- AC Hum, 107
3.3.5.3- Eddy Current, 109
3.3.5.4- Inrush Current, 110
3.3.5.5- Performance of AC Switching Solenoids for EH Valves, 113
3.3.5.6- Applications of AC switching Solenoids for EH Valves, 114
3.3.6- DC versus AC Switching Solenoid, 114
3.3.7- Electrical Ratings for Switching Solenoids, 115
3.3.8- Manual Override, 116
3.3.9- Switching Solenoids for Cartridge Valves, 117
3.3.10- Standard Electrical Terminations for Switching Solenoids, 118

3.4- Electro-Hydraulic Switching Directional Control Valves, 120

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3.5- Electro-Hydraulic Switching Pressure Control Valves, 131

3.6- Electro-Hydraulic Switching Flow Control Valves, 133

Chapter 4: Electrical Circuits for Switching Valves, 134

4.1- Best Practices for Safe Operation of Electro-Hydraulic Systems, 135
4.2- Basic Electrical Symbols, 140
4.3- Basic Electrical Devices, 142
4.3.1- Measuring Instruments, 142
4.3.2- Electrical Pushbuttons and Switches, 144
4.3.3- Limit Switches, 145
4.3.4- Proximity Switches, 146
4.3.5- Pressure Switches, 147
4.3.6- Fluid Flow Switches, 148
4.3.7- Fluid Level Switches, 148
4.3.8- Temperature Switches, 149
4.3.9- Control Relays, 149
4.3.10 - Programmable Logic Controllers (PLCs), 151

4.4- Electrical Schematic Diagrams, 153

4.4.1- JIC Schematic Diagrams, 153
4.4.2- Wiring Diagrams, 156
4.4.3- Sequence Diagrams, 157

4.5- Electrical Circuits for Applications of Switching Valves, 158

4.5.1- Identity (YES Function) by Direct Activation, 158
4.5.2- Negation (NOT Function) by Direct Activation, 159,
4.5.3- Identity (YES Function) by Indirect Activation, 160
4.5.4- Negation (NOT Function) by Indirect Activation, 161
4.5.5- Signal Storage by Electrical Latching, 162
4.5.6- Electromechanical Protection of a Valve with Two Solenoids, 163
4.5.7- Electrical Protection of a Valve with Two Solenoids, 164
4.5.8- Position-Dependent Cylinder Deceleration, 167
4.5.9- One-Cycle Hydraulic Cylinder Reciprocation, 171
4.5.10- Continuous Cylinder Reciprocation, 173
4.5.11- Panic Circuit, 176
4.5.12- Conjunction Functions, 177
4.5.13- Disjunction Functions, 181
4.5.14- Timer Circuits, 183
4.5.15- Sequence Control, 185
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Chapter 5: Proportional Valves, 191

5.1- Introduction to Proportional Valves, 192
5.2- Proportional Solenoids, 196
5.2.1- Force-Controlled Proportional Solenoid, 196
5.2.2- Stroke-Controlled Proportional Solenoid, 200

5.3- Proportional Directional Control Valves, 204

5.3.1- Interpretation of Symbols for Proportional Directional Valves, 204
5.3.2- Hydraulic Static Characteristics of Proportional Directional Valves, 205
5.3.3- Direct-Operated Force-Controlled Proportional Directional Valve, 207
5.3.4- Direct-Operated Stroke-Controlled Proportional Directional Valve, 210
5.3.5- High Performance Proportional Directional Valve, 213
5.3.6- Pilot-Operated Force-Controlled Proportional Directional Valve, 218
5.3.7- Pilot-Operated Stroke-Controlled Proportional Directional Valve, 225
5.3.8- Proportional Directional Valves with Variable Load Compensator, 232

5.4- Proportional Pressure Control Valves, 236

5.4.2- Hydraulic Static Characteristics of Proportional Pressure Relief Valves, 237
5.4.3- Direct-Operated Force-Controlled Proportional Pressure Relief Valves, 238
5.4.4- Direct-Operated Stroke-Controlled Proportional Pressure Relief Valves, 242
5.4.5- Pilot-Operated Force-Controlled Proportional Pressure Relief Valves, 244
5.4.6- Pilot-Operated Stroke-Controlled Proportional Pressure Relief Valves, 251
5.4.7- Proportional Pressure Reducing Valves, 252

5.5- Proportional Flow Control Valves, 254

5.6- Proportional Valves for Mobile Applications, 259

Chapter 6: Servo Valves, 260

6.1- Introduction to Servo Hydraulics, 261
6.1.1- Historical Background, 261
6.1.2- Servo Valve Applications, 261

6.2- Torque Motors, 264

6.2.1- Torque Motor Construction and Operation, 264
6.2.2- Torque Motor Wiring, 266
6.2.2.1- Parallel Wiring, 266
6.2.2.2- Series Wiring, 267
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6.2.2.3- Single Wiring, 268

6.3- Servo Valve Configurations, 269

6.3.1- Power Assistance using Mechanical Servo Valve, 269
6.3.2- Single-Stage Servo Valve, 271
6.3.3- Two-Stage Servo Valve with Tracking Sleeve, 273
6.3.4- Flapper–Nozzle Concept of Operation, 275
6.3.4.1- Half-Bridge Flapper-Nozzle Concept, 275
6.3.4.2- Full-Bridge Flapper-Nozzle Concept, 277
6.3.4.3- Power Gain of Servo Valve, 279
6.3.5- Two-Stage Flapper–Nozzle Servo Valve with Barometric Feedback, 280
6.3.6- Two-Stage Flapper–Nozzle Servo Valve with Mechanical Feedback, 282
6.3.7- Two-Stage Flapper–Nozzle Servo Valve with Electrical Feedback, 292
6.3.8- Two-Stage Flapper–Nozzle Servo Valve with Mechanical and Electrical Feedback, 294
6.3.9- Three-Stage Flapper–Nozzle Servo Valve, 295
6.3.10- Jet Pipe Concept of Operation, 299
6.3.11- Two-Stage Jet Pipe Servo Valve with Mechanical Feedback, 300
6.3.12- Two-Stage Jet-Pipe Servo Valve with Electrical Feedback, 304
6.3.13- Jet Pipe versus Flapper-Nozzle Pilot Stage, 206
6.3.14- Two-Stage Jet-Deflector Servo Valve with Mechanical Feedback, 307

Chapter 7: Electro-Hydraulic Valve Selection Criteria, 309

7.1- Importance of Proper Selection of an EH Valve, 310
7.2- Electro-Hydraulic Valve Selection Criteria, 311
7.3- Valve Type, 312
7.4- Valve Spool Design, 316
7.4.1- Spool Null Conditions, 316
7.4.1.1-Overlapped (Closed-Center) Null Conditions, 317
7.4.1.2- Zero-Lapped (Critical-Center) Null Conditions, 319
7.4.1.3- Underlapped (Open-Center) Null Conditions, 320
7.4.2- Spool Transitional Conditions, 323
7.4.3- Spool Fail-Safe Position, 324
7.4.4- Spool Control Edges, 325
7.4.4.1- Holes versus Control Edges, 325
7.4.4.2- Custom Control Edges, 326
7.4.4.3- Standard Control Edges, 326
7.4.4.4- Distribution of Control Edges, 332

7.5- Valve Static Characteristics, 334

7.5.1-Valve Flow Gain, 335
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7.5.2- Valve Flow-Pressure Coefficient, 345

7.5.3-Power Limits, 350
7.5.4-Pressure Gain, 353
7.5.5-Valve Sizing, 355
7.5.6-Valve Hysteresis, 367

7.6-Valve Dynamic Characteristics, 370

7.6.1-Step Response, 370
7.6.2-Frequency Response, 376

7.7-Valve Operating Conditions, 383

7.8-Examples of Published Data, 383

Chapter 8: Open-Loop versus Closed-Loop EH Applications, 392

8.1- Electro-Hydraulic Open-Loop Control Systems, 393
8.1.1- Structure of Electro-Hydraulic Open-Loop Control Systems, 393
8.1.2- Features of Electro-Hydraulic Open-Loop Control Systems, 394
8.1.3- Electro-Hydraulic Open-Loop Speed Control Systems, 395
8.1.4- Electro-Hydraulic Open-Loop Load Control Systems, 397

8.2- Electro-Hydraulic Closed-Loop Control Systems, 400

8.2.1- Structure of Electro-Hydraulic Closed-Loop Control Systems, 400
8.2.2- Features of Electro-Hydraulic Closed-Loop Control Systems, 401
8.2.3- Electro-Hydraulic Closed-Loop Speed Control Systems, 403
8.2.3.1- Electro-Hydraulic Closed-Loop Flow Control System, 403
8.2.3.2- Electro-Hydraulic Closed-Loop Motor Speed Control System, 406
8.2.4- Electro-Hydraulic Closed-Loop Load Control Systems, 408
8.2.4.1- EH Closed-Loop Single-Acting Cylinder Pressure Control System, 408
8.2.4.2- Electro-Hydraulic Closed-Loop Single-Acting Cylinder Force Control System, 411
8.2.4.3- EH Closed-Loop Double-Acting Cylinder Pressure Control System, 412
8.2.4.4- EH Closed-Loop Double-Acting Cylinder Force Control System, 415
8.2.5- Electro-Hydraulic Closed-Loop Position Control Systems, 416

8.3- Closed-Loop Performance Analysis, 420

8.4- Electro-Hydraulic Control Systems Applications Examples, 422
8.4.1- Industrial Applications, 422
8.4.2- Mobile Applications, 430

Chapter 9: Control Electronics for Electro-Hydraulic Valves, 437

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9.1- Control Electronics Basic Functions, 438

9.2- DC Power Supply, 441
9.3- Signal Amplifier, 442
9.4- Dither Signal, 443
9.5- Pulse Width Modulation, 443
9.6- Input Signal Generator, 447
9.6.1- Format of Input Signal, 447
9.6.2- Source and Mode of Input Signal, 448

9.7- Feedback Sensors, 450

9.8- PID Controller, 450
9.9- Gain Adjustor, 453
9.10- Ramp Adjustor, 456
9.11- Null Adjustor (IBias), 459
9.12- Dead Band Eliminator (Imin), 462
9.13- Saturation Adjustor (Imax), 465
9.14- Control Electronics Basic Configurations, 467
9.15- Hardware Configuration, 468
9.16- Typical Electronic Schematics for Continuous Valves, 469

Chapter 10: Electro-Hydraulic Valves Commissioning and Maintenance, 504

10.1- Installation and Commissioning Instructions, 505
10.1.1- Cleanliness, 505
10.1.2- Installation Position (review phrasing on the slide), 506
10.1.3- Mounting Screws, 506
10.1.4- Seals (rephrase on the slide), 506
10.1.5- Electrical Connections, 506
10.1.6- Storage Locations, 506

10.2- Filtration Requirements, 507

10.2.1-Reservoir Breather Filter, 507
10.2.2-Filtration, 507
10.2.3- System Flushing, 511

10.3- Electro-Hydraulic Valve Tests and Maintenance, 512

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APPENDIXES, 513
APPENDIX A: LIST OF FIGURES, 513
APPENDIX B: LIST OF TABLES, 531
APPENDIX C: LIST OF ANIMATED CIRCUITS (AUTOMATION STUDIO), 531
APPENDIX E: LIST OF REFERENCES, 533

INDEX, 542