IoT-enabled intelligent electro-hydraulic servo valve system

Abstract

A system for an IoT-enabled intelligent electrohydraulic servo valve, including: an ESP32 microcontroller configured to generate an analog control signal according to a desired actuation level and communicate wirelessly via Wi-Fi and / or Bluetooth connectivity for Internet of Things (IoT) applications; a signal conditioning circuit electrically connected to the ESP32 microcontroller, wherein the signal conditioning circuit is configured to amplify and convert a low-voltage digital-to-analog converter (DAC) output signal of the microcontroller in the range of 0 to 3.3 volts into an analog control signal in the range of ±10 volts suitable for operating an industrial servo valve; an electro-hydraulic servo valve functionally coupled to the signal conditioning circuit, wherein the servo valve is configured to control the hydraulic fluid flow and pressure between multiple ports in response to the analog control signal, thereby enabling bidirectional flow control of a hydraulic actuator; and a wireless communication interface configured to transmit operational data and receive command input from a remote computer or control unit for real-time monitoring, diagnostics, and predictive maintenance. the system is programmable using open-source platforms to implement linear, non-linear or artificial intelligence-based control algorithms, and is compatible with existing industrial automation or PLC-based systems.

Description

[0001] The present invention relates to the field of electrohydraulic control systems and, in particular, an IoT-enabled intelligent electrohydraulic servo valve designed for industrial automation applications. The invention lies at the interface between mechatronics, control engineering, and the Internet of Things (IoT) and integrates wireless connectivity, artificial intelligence (AI), and machine learning (ML) into conventional hydraulic servo systems.

[0002] Electrohydraulic servo valves are widely used in industrial automation systems, including robotics, earthmoving equipment, aerospace propulsion, rolling mills, and precision test benches. These valves play a crucial role in controlling the flow and pressure of hydraulic fluid in response to electrical control signals, enabling precise positioning, speed, and force control of actuators. In conventional systems, the operation of electrohydraulic servo valves is primarily controlled by programmable logic controllers (PLCs) or other wired controllers. While effective, these systems suffer from limited adaptability, a lack of wireless connectivity, and insufficient integration with modern digital technologies such as the Internet of Things (IoT), artificial intelligence (AI), and machine learning (ML).The implementation of nonlinear control algorithms or predictive remote maintenance is often limited by communication and compatibility issues between traditional PLCs and intelligent computing platforms. Existing industrial servo systems also suffer from high hardware costs and limited interoperability with open-source technologies, hindering innovation and flexibility in system design. Furthermore, most available electrohydraulic servo valves lack real-time monitoring or cloud-based data analytics capabilities that could improve fault detection and overall system efficiency. Therefore, there is a need for a cost-effective, IoT-enabled, and AI-compatible electrohydraulic servo valve that offers wireless communication, remote control, and predictive diagnostics.The present invention overcomes these limitations by integrating an ESP32 microcontroller, a signal conditioning circuit, and industrial-grade servo valve hardware to create an intelligent, network-enabled system suitable for next-generation industrial automation and intelligent control applications.

[0003] To solve this problem, the present invention offers an IoT-enabled intelligent electro-hydraulic servo valve system.

[0004] The system enables intelligent control and monitoring of hydraulic actuators through wireless connectivity and the integration of artificial intelligence (AI) and machine learning (ML) algorithms.

[0005] The system uses an ESP32 microcontroller with integrated Wi-Fi and IoT functions to send and receive control signals for the precise actuation of an industrial-grade electro-hydraulic servo valve.

[0006] The system enables remote monitoring, control and diagnostics of electrohydraulic systems in real time using IoT communication protocols, thus supporting predictive maintenance and reducing system downtime.

[0007] The system offers a cost-effective and open-source compatible control architecture that enables researchers and industrial companies to implement, test, and optimize advanced linear and nonlinear control strategies using Python or similar environments.

[0008] The system can be integrated into existing PLC-controlled environments, thus increasing the flexibility of automation without requiring major hardware changes.

[0009] The system enables the development of intelligent electro-hydraulic drive systems that combine mechanical precision with AI-controlled adaptability, thus contributing to the further development of Industry 4.0 and intelligent factory ecosystems.

[0010] In one embodiment, the present invention relates to an IoT-enabled intelligent electrohydraulic servo valve system. The present disclosure provides a system for an IoT-enabled intelligent electrohydraulic servo valve that integrates wireless connectivity, artificial intelligence (AI), and machine learning (ML) into an industrial-grade electrohydraulic drive system. The disclosed system overcomes the limitations of conventional PLC-based control architectures by introducing a compact, cost-effective, and programmable controller suitable for remote operation and intelligent monitoring. In one embodiment, the system comprises an ESP32 microcontroller, a signal conditioning circuit, and a quad electrohydraulic directional control valve.The ESP32 microcontroller generates analog control signals in the range of 0-3.3 V via its digital-to-analog converter (DAC) pins. These signals are processed by the signal conditioning circuitry to produce an output voltage of ±10 V, suitable for driving an industrial-grade servo valve such as the Bosch Rexroth 4WS2EM6-22 / 10B11ET315K17DV. The ESP32 microcontroller offers Wi-Fi and IoT connectivity, enabling wireless communication between the servo valve and remote computers or control devices. Through open-source programming environments such as Python or MicroPython, the system allows for the implementation and testing of linear and nonlinear control algorithms, as well as AI- and ML-based adaptive control models. The open system enables real-time monitoring, diagnostics, and predictive maintenance by collecting operational data and transmitting it to remote servers or cloud platforms via IoT networks.This facilitates data-driven decision-making and increases the system's reliability and efficiency. In another embodiment, the system can be easily integrated into existing PLC-based or industrial automation frameworks, ensuring backward compatibility while achieving high control flexibility. By using cost-effective microcontroller hardware and an op-amp-based signal conditioning circuit, the system is economically viable for industrial and research applications. Accordingly, the present disclosure provides an intelligent, IoT-enabled electrohydraulic servo valve system that combines mechanical precision, digital intelligence, and wireless interoperability to support the development of intelligent industrial systems and Industry 4.0 environments. The invention will be explained again below.

[0011] The present disclosure relates to an IoT-enabled intelligent electrohydraulic servo valve system that enables intelligent control, wireless communication, and predictive monitoring of hydraulic drive systems. The system integrates a microcontroller-based control unit, a signal conditioning circuit, and an industrial-grade electrohydraulic servo valve to enable advanced automation and control functions. In one embodiment, the system comprises an ESP32 microcontroller, a signal conditioning circuit, and an industrial-grade electrohydraulic servo valve. The ESP32 microcontroller is configured to generate an analog control signal corresponding to the desired actuation level.The signal conditioning circuit is connected to the ESP32 output pin and configured to amplify the low-voltage control signal (0-3.3 V) and convert it into a bipolar voltage signal (±10 V) suitable for controlling the industrial servo valve. The servo valve is a four-way directional valve configured to control the hydraulic fluid flow between ports P, A, B, and T depending on the polarity and magnitude of the control signal. A positive command signal directs flow from port P to port A and from port B to port T, while a negative command signal reverses the flow direction from port P to port B and from port A to port T. In another embodiment, the ESP32 microcontroller is programmed with Python or MicroPython and configured for wireless communication via Wi-Fi or Bluetooth protocols.The microcontroller receives command signals and transmits real-time operational data, such as pressure, position, and valve status, to a remote computer or cloud-based platform. This enables remote monitoring, diagnostics, and control of the servo valve via an IoT-based infrastructure. The system can be further configured to implement AI and ML algorithms for predictive maintenance, adaptive control, and anomaly detection, thereby improving the reliability and intelligence of the hydraulic actuation system. In another embodiment, the signal conditioning circuit includes an operational amplifier (op-amp), preferably an IC741, configured as a differential amplifier. The circuit is powered by a dual ±12 V DC supply to achieve the required gain and output range.The resistor network is designed to ensure the desired gain and signal symmetry, maintaining high linearity between the control input and the servo valve output. This design guarantees compatibility between the outputs of low-voltage microcontrollers and the input requirements of industrial-grade servo valves. In another embodiment, the system integrates an industrial four-way servo valve, such as the Bosch Rexroth 4WS2EM6-22 / 10B11ET315K17DV, which operates at 15 V DC and requires a ±10 V control input. The ESP32 microcontroller provides the necessary analog control voltage via the signal conditioning circuit to precisely actuate the valve.The system is also able to interface with existing PLC-based automation frameworks or open-source industrial IoT systems, ensuring backward compatibility and cost-effective modernization of conventional electrohydraulic systems.

Claims

[1] A system for an IoT-enabled intelligent electrohydraulic servo valve, comprising: an ESP32 microcontroller configured to generate an analog control signal according to a desired actuation level and communicate wirelessly via Wi-Fi and / or Bluetooth connectivity for Internet of Things (IoT) applications; a signal conditioning circuit electrically connected to the ESP32 microcontroller, wherein the signal conditioning circuit is configured to amplify and convert a low-voltage digital-to-analog converter (DAC) output signal of the microcontroller in the range of 0 to 3.3 volts into an analog control signal in the range of ±10 volts suitable for operating an industrial servo valve; an electro-hydraulic servo valve functionally coupled to the signal conditioning circuit, wherein the servo valve is configured to control the hydraulic fluid flow and pressure between multiple ports in response to the analog control signal, thereby enabling bidirectional flow control of a hydraulic actuator; and a wireless communication interface configured to transmit operational data and receive command input from a remote computer or control unit for real-time monitoring, diagnostics, and predictive maintenance. the system is programmable using open-source platforms to implement linear, non-linear or artificial intelligence-based control algorithms, and is compatible with existing industrial automation or PLC-based systems. [2] The system according to claim 1, wherein the signal conditioning circuit comprises an operational amplifier (Op-Amp), preferably an IC741, configured as a differential amplifier to convert and amplify the low-voltage control signal from the ESP32 microcontroller into an output signal of ±10 volts. [3] System according to claim 1 or 2, wherein the signal conditioning circuit is powered by two DC power supplies of +12 volts and -12 volts to maintain linear amplification and ensure compatibility with the industrial-grade servo valve. [4] System according to any of the preceding claims, wherein the electrohydraulic servo valve is a four-way directional valve configured to direct the hydraulic fluid flow between ports P, A, B and T depending on the polarity and magnitude of the input control signal. [5] System according to claim 4, wherein a positive control signal causes a fluid flow from port P to port A and from port B to port T and a negative control signal causes a fluid flow from port P to port B and from port A to port T. [6] System according to any of the preceding claims, wherein the ESP32 microcontroller is programmed using Python or MicroPython and configured to communicate wirelessly with a remote computer device, an IoT server or a cloud-based platform for real-time control, monitoring and data acquisition. [7] System according to any of the preceding claims, wherein the IoT-enabled communication interface is configured to implement predictive maintenance algorithms by transmitting operational data and receiving diagnostic feedback via IoT protocols such as MQTT, HTTP or similar communication standards. [8] System according to any of the preceding claims, wherein the system is configured to communicate with existing PLC-based automation frameworks, thereby ensuring backward compatibility and enabling seamless integration into industrial control environments.