Study on flow force compensation characteristics and optimization design of jet guiding groove

A jet guiding groove is designed on the spool to compensate the steady-state flow force. The steady-state flow force model is analyzed and derived. The influence of structural parameters on steady-state flow force is studied by CFD simulation. The response surface method is used to construct the steady-state flow force polynomial regression model. The optimal structure size of the jet guiding groove is obtained. The steady-state flow force compensation coefficient is defined and calculated. Results show that the compensation effect decreases with the increase of pressure difference. However, at the same pressure difference, the absolute value of the compensation coefficient of the spool with jet guiding groove is less than that of the spool without jet guiding groove. The results show that the jet guiding groove can effectively compensate the steady-state flow force and improve the control accuracy of the valve.     

Transient flow analysis on opening process of pneumatic gas proportional valve with two-solenoid valve

The gas proportional valve (GPV) is a pneumatic pressure regulator, and the change in operating pressure will directly affect the opening and closing condition of the spool. In this study, the procedure for opening the spool is studied. The process of regulating the pressure of the GPV is revealed by the dynamical simulation method. The characteristics of displacement, total pressure and velocity of the spool during opening are analyzed. As time increases, it is found that the turbulence in the downstream of GPV becomes more obvious. In the process of spool movement, the influence of different inlet working pressures on spool displacement is analyzed. With a full open time of less than 1.5 × 10^ (−2) s, the spool reaches the stable state of full opening. In addition, the transient process of outlet flow is also studied. The simulated outlet flow is stable at 152 m³/h for the maximum opening. In order to verify the simulation results, the test of valve flow is carried out on the test bench. The results show that these methods can reduce the design difficulty and provide a reference for further optimization and engineering application of GPV.     

机器人打磨系统力控补偿优化算法研究

针对目前打磨机器人在复杂环境中不能兼具磨削精度和顺应性等问题,提出了一种基于算法优化的机器人打磨系统力 控补偿方法。 首先,阐述了机器人打磨系统的力学特性及力控优化算法原理;然后搭建了实验系统,进行了机器人容许响应范 围及主动柔顺恒力磨削实验,最后,采用扩展 Kalman 滤波算法、最小二乘拟合算法和粒子滤波算法优化打磨力的实时补偿值, 并对比了各算法的补偿效果。 实验结果表明,通过力控补偿功能,在 20 mm 内可实现 100% 对系统结构误差的补偿;与设定期 望打磨力比较,平均相对误差为 5. 44% ;利用扩展 Kalman 滤波算法、最小二乘拟合算法和粒子滤波算法优化后平均误差分别降 低至 1. 20% 、1. 24% 和 1. 64% 。 拓展优化机器人协同力控系统的实时力/ 位补偿功能,将有助于提高机器人打磨系统的精度和 稳定性,为机器人技术的发展提供理论依据和技术支持。     

高速大流量插装式比例节流阀的建模与验证

插装式比例节流阀在高速大流量时表现出强非线性,在高速、高精度电液伺服系统设计中,其模型不能简单地视为线性系统.分析插装式比例节流阀的工作机理,建立了插装式比例节流阀简单、实用的非线性数学模型.模型计算值与实验数据的比较表明,该模型能较准确地描述阀的动/静态特性.     

Parameter tuning method for dither compensation of a pneumatic proportional valve with friction

In the practical application of pneumatic control devices, the nonlinearity of a pneumatic control valve become the main factor affecting the control effect, which comes mainly from the dynamic friction force. The dynamic friction inside the valve may cause hysteresis and a dead zone. In this paper, a dither compensation mechanism is proposed to reduce negative effects on the basis of analyzing the mechanism of friction force. The specific dither signal (using a sinusoidal signal) was superimposed on the control signal of the valve. Based on the relationship between the parameters of the dither signal and the inherent characteristics of the proportional servo valve, a parameter tuning method was proposed, which uses a displacement sensor to measure the maximum static friction inside the valve. According to the experimental results, the proper amplitude ranges are determined for different pressures. In order to get the optimal parameters of the dither signal, some dither compensation experiments have been carried out on different signal amplitude and gas pressure conditions. Optimal parameters are determined under two kinds of pressure conditions. Using tuning parameters the valve spool displacement experiment has been taken. From the experiment results, hysteresis of the proportional servo valve is significantly reduced. And through simulation and experiments, the cut-off frequency of the proportional valve has also been widened. Therefore after adding the dither signal, the static and dynamic characteristics of the proportional valve are both improved to a certain degree. This research proposes a parameter tuning method of dither signal, and the validity of the method is verified experimentally.     

Deadzone compensation control based on detection of micro flow rate in pilot stage of proportional directional valve

The pilot operated proportional directional valves (POPDVs) with a flow rate ranging from 100 to 1000 L/min are widely used in electro-hydraulic systems (EHSs). The deadzone of the pilot stage valve and its control compensation could significantly affect the position control performance for the main stage valve that could directly affect dynamics of EHSs In this paper, it is concluded that micro flow rates exist at the intermediate position of the valve based on the analysis of the continuity equation of the flow in the control chamber of the pilot stage. The micro flow rate is helpful to eliminate the discontinuity and unsmooth domain in the previous inverse deadzone compensation function. An improved deadzone detection method is proposed to calibrate the pilot valve flow characteristics which include the micro flow rate. This new method avoids the threshold selection of the main valve spool displacement which affects the detected deadzone values. Its detection processes are realized based on the pilot flow rate characterized by the speed of the main valve spool and the pilot valve displacement characterized by the solenoid current. The deadzone compensation control strategy based on the improved deadzone detection method is also designed. The experimental results using the steady-state position tracking and sinusoidal position tracking methods are verified. It is concluded that the tracking accuracy of the main valve spool position is effectively improved with this control strategy.     

称重传感器的横向灵敏度及横向力补偿

称重传感器在大多数称量实践中,总是伴随出现横向力(力矩)的干扰,而产生横向灵敏度。本文分析了引起横向灵敏度的诸因素及其对称量结果的影响。指出横向灵敏度的大小取决于弹性元件的结构形状,压头、底垫、安装平台等附件的性能,若有5%的横向力存在,会在高准确度称重传感器中出现满量程±0.1%的偏差;在普通准确度称重传感器中出现±0.6%的偏差。并以圆柱式称重传感器为例,介绍了利用单层或双层环形膜片与弹性元件和外壳焊接,补偿横向力和弯曲力矩的原理和工艺方法,给出了圆形膜片的挠度和应力计算公式。     

Research on back- pressure compensation characteristics of a pilot-assisted load control valve applied in overrunning load hydraulic systems

This paper reports the research of proportion flow control with back-pressure compensation feature on an LCV (load control valve). The back-pressure compensation feature means when back-pressure rises, flow of the LCV can be unchanged or lower. The back-pressure compensation feature is very important to the safety of the system, because high back-pressure will make the main valve open larger and lowering speed be undesired faster. In this paper, static equilibrium equations of LCV were established and influence relationship of back-pressure and other parameters was derived. In addition, back-pressure influence was simulated, based on above analysis a preliminary optimization scheme was proposed and tested. After that, the method of back-pressure compensation was proposed and has been verified by simulation. Finally, an LCV with back-pressure compensation feature was tested on the test rig. Experiment data validates that the main flow of the LCV with back-pressure compensation method was lower under a higher back-pressure and the pilot pressure control region was unchanged.     

Force control compensation method with variable load stiffness and damping of the hydraulic drive unit force control system

Each joint of hydraulic drive quadruped robot is driven by the hydraulic drive unit (HDU), and the contacting between the robot foot end and the ground is complex and variable, which increases the difficulty of force control inevitably. In the recent years, although many scholars researched some control methods such as disturbance rejection control, parameter self-adaptive control, impedance control and so on, to improve the force control performance of HDU, the robustness of the force control still needs improving. Therefore, how to simulate the complex and variable load characteristics of the environment structure and how to ensure HDU having excellent force control performance with the complex and variable load characteristics are key issues to be solved in this paper. The force control system mathematic model of HDU is established by the mechanism modeling method, and the theoretical models of a novel force control compensation method and a load characteristics simulation method under different environment structures are derived, considering the dynamic characteristics of the load stiffness and the load damping under different environment structures. Then, simulation effects of the variable load stiffness and load damping under the step and sinusoidal load force are analyzed experimentally on the HDU force control performance test platform, which provides the foundation for the force control compensation experiment research. In addition, the optimized PID control parameters are designed to make the HDU have better force control performance with suitable load stiffness and load damping, under which the force control compensation method is introduced, and the robustness of the force control system with several constant load characteristics and the variable load characteristics respectively are comparatively analyzed by experiment. The research results indicate that if the load characteristics are known, the force control compensation method presented in this paper has positive compensation effects on the load characteristics variation, i.e., this method decreases the effects of the load characteristics variation on the force control performance and enhances the force control system robustness with the constant PID parameters, thereby, the online PID parameters tuning control method which is complex needs not be adopted. All the above research provides theoretical and experimental foundation for the force control method of the quadruped robot joints with high robustness.     

Development of a flow control valve with digital flow compensator

Flow control valves typically use mechanical pressure drop compensator or dynamic flow meter to lessen the impact of pressure drop on outlet flow. However, there are some disadvantages, such as complex mechanical structure and small flow capacity. In this paper, a kind of digital flow compensator with bilinear interpolation algorithm is presented to compensate the pressure drop, in which the pressure drop and the desired outlet flow are the two input parameters. A two-stage proportional flow control valve with the proposed compensator is investigated. Pressure drop across the metering orifice of the valve is measured and fed back to the proposed compensator. If the detected pressure drop has deviated from the threshold, then the compensator will generate a compensation signal to adjust the poppet opening of the valve, which ensures that the output flow is independent of the pressure drop. Performances of the valve with the proposed compensator are investigated by simulation and experiment. Results show that it has a reasonable static control characteristics. In addition, there is no dead-zone in its steady flow curve; pressure drop have little impact on its output flow. Its dynamics will be affected by pressure drop and input voltage. Increasing pressure drop can improve system dynamics under constant input signal conditions. On the other hand, increasing input signal can shorten the poppet's closing time, but it will result in the longer opening time and the greater overshoot in the opening stage.     

比例调节气动阀结构与静力分析

分析了新型比例调节气动阀的结构以及工作原理,并对该阀进行了静力分析,通过给定的参数,计算并绘制出了该阀的调节特性曲线,指出了该阀的应用场合以及现实意义。     

A hybrid of surrogate model and MIGA method for optimization and compensation of steady-state flow force on water hydraulic HSV

In this research, a hybrid of surrogate model and Multi-island genetic algorithm (MIGA) is proposed for optimization and compensation of steady-state flow force on water hydraulic high-speed on-off valve (HSV) driven by voice coil motor. Firstly, a dynamic model on the spool of HSV is established, and the effects of spool displacement, spool half-cone angle, valve stem diameter and inlet pressure on the steady-state flow force of HSV are analyzed through the CFD simulation. Secondly, a quadratic response surface model is set up based on design of experiment (DOE) to analyze interactions of key parameters on steady-state flow force. MIGA is proposed to optimise the structural parameters of HSV, and the optimization results are analyzed and verified by CFD simulations. Simulation results demonstrate that the steady-state flow force is reduced significantly. Finally, the steady-state flow force in the optimized structure of HSV is also verified experimentally. The experiment results exhibit that the optimized spool can compensate about 71% for the steady-state flow force, then reduce about 15% the energy consumption of HSV. This research will provide the guide for the design and engineering application of HSV.     

Effect of the convergence flow conditioner on rectifying eccentric jet flow induced by a ball valve

Installing a flow conditioner is an important method for rectifying irregular and unstable flow to stable flow state within a short flow distance in fluid transportation and control industrial applications. However, classical flow conditioners (such as Laws and Zanker flow conditioners in ISO 5167) with parallel pipeline axial orifices ineffectively rectify the distinct eccentric jet flow caused by valve regulation. The convergence flow conditioner with convergent orifices was innovatively designed for rectifying the eccentric jet flow caused by a ball valve in this study. Three convergent orifice angles (8°, 10°, and 12°) defined as angles between orifice and pipeline axes were considered to compare their effect on eccentric jet flow rectification as well as with the classical Laws flow conditioner (characterized by the convergent orifice angle of 0°) under different valve openings with an experimental setup for monitoring downstream pressures that develop along the pipeline and corresponding numerical simulation used. Pressure loss and throttling effect of installing convergence flow conditioners downstream the ball valve was assessed. Analysis of distributions of the pressure, velocity, and streamline for convergent flow conditioners showed that the flow conditioner with a large convergent orifice angle can effectively improve violent eccentric jet flows, especially under a small valve opening. The axial velocity on various downstream cross sections was extracted to evaluate the velocity uniformity. A dimensionless parameter of velocity eccentric ratio was used to quantify the rectification effect of eccentric jet flow evolving in the downstream pipeline. Results showed that a short pipeline length is needed to obtain additional symmetry and uniform flow field downstream of the flow conditioner with a high convergent orifice angle, that is, the convergence flow conditioner with a high convergent orifice angle demonstrated a strong effect of flow rectification on the valve-induced eccentric jet flow. This work can help understand characteristics of flow rectification on valve-induced eccentric jet flow in scientific research, and provide guidance for the flow conditioner design in fluid engineering.     

V形调节球阀的结构优化

利用计算流体力学CFD软件,研究V形调节球阀在不同开度下的流量特性并进行数值模拟分析。结合实验数据,优化V形切口形状,使其与理想的流量特性趋于一致,提高了阀门的调节性能。     

几种节流阀受力状况的定性分析及其优选

节流阀是油田井控管汇上普遍应用的一种阀件.基于对节流阀的安全性及存在的问题阐述,为设计高效的压井系统,提供了可靠的实际应用中安全、适用的节流装置选择的理论依据.从流体力学理论的角度,对四种节流阀受力状况作了定性分析,并提出了改进意见和压井施工中应优先考虑选用套阀和楔型阀,以提高压井的安全性.     

基于电液比例溢流阀的模拟加载系统研究

针对某液压起竖设备模拟加载实验的需要,设计了基于电液比例溢流阀的模拟加载系统。介绍了系统的组成和工作原理,分析了液压缸的载荷特性。通过AMEsim软件和Matlab／Simulink软件,对模拟加载系统进行了机电液协同仿真研究。仿真结果表明,反腔压力能够较好地跟踪理论值。     

Analysis and compensation for the cascade dead-zones in the proportional control valve

The four-way proportional directional control valve has been widely used as the main stage spring constant for the two-stage proportional control valve (PDV). Since a tradeoff should be made between manufacturing costs and static performance, two symmetry dead-zones are introduced in the main stage spring constant: the center dead-zone caused by the center floating position and the intermediate dead-zone caused by the intermediate position. Though the intermediate dead-zone is much smaller than the center dead-zone, it has significant effect on the dynamic position tracking performance. In this paper, the cascade dead-zones problem in a typical two-stage PDV is analyzed and a cascade dead-zones model is proposed for the main stage spring constant. Then, a cascade dead-zones inverse method is improved with gain estimation and dead-zone detection to compensate the dead-zone nonlinearity. Finally, a digital controller is designed for verification. The comparative experimental results indicate that it is effective to reduce the large position tracking error when the proposed method is applied.     

Flow disturbance compensation calculated with flow simulations for ultrasonic clamp-on flowmeters with optimized path arrangement

Ultrasonic clamp-on flowmeters (USCF) are popular among measurement technologies due to the versatility of applications, increasing accuracy, and easy, non-intrusive mounting, with the sensors being mounted directly on the external surface of the pipe. In industrial applications, installation space is usually restricted and therefore, flowmeters must be mounted often directly downstream of flow disturbances (FD). A major issue of USCF is the long inlet run needed downstream of FD to achieve a measurement within the specified accuracy. A configuration of two V-paths is proposed, axially rotated 90° relative to each other, that compensates for the flow error introduced due to disturbed flow conditions, independent of the rotational position of the flowmeter. Flow disturbance compensation (FlowDC) is achieved, i.e., accurate measurements within the specification of 2% flow rate accuracy, when the flowmeter is mounted as close as 2 pipe diameters (D) downstream of a FD. Computational fluid dynamics (CFD) are employed to generate rotationally independent correction factors that compensate for the error introduced from disturbed inlet conditions. An automated simulation method is developed to generate correction factors for 90° bend, out-of-plane bend, expansion, and contraction, at mounting distances from 2D to 100D, several flow rates, and rotational positions 0°, 90°, 180°, 270°. This study would be practically impossible with non-automated simulations or solely with measurements. In-house experiments were performed with an industrial clamp-on device at selected distances from the FD with the aim of verifying the simulation results. An independent field-test is presented that showcases the value of FlowDC in USCF applications. The automated simulations have the capability to simulate further FDs on-demand, with the aim of creating a database for the needs of the respective application in industry.