Hydraulic Controller Auto-Tuning from Measurement Data
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Solution Overview
Problem
Hydraulic systems face challenges with controller configuration due to wear-related issues in mechanical controllers and dependency on human settings for electronic controllers, limited sensor availability, and non-linearities like hysteresis and friction, which affect control quality and adaptability.
Innovation Solution
An automated method for configuring an electronic controller using measurement data, combining machine learning and control engineering to identify system behavior and synthesize controllers that can adapt to changing conditions, optimizing control quality and energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If PID controllers are used for hydraulic systems, then electronic control is achieved, but control quality is heavily dependent on human settings and conditions
Solution Approach 1:
The system performs self-identification and self-tuning by automatically acquiring measurement data from sensors, identifying system behavior using computer-based models, and synthesizing optimal controller parameters without requiring manual configuration by operators
Solution Approach 2:
The system executes a predefined measurement routine before normal operation to collect system response data, which is then used to identify system behavior and preconfigure optimal controller parameters for subsequent operation
2Ease of manufacture
If predefined mathematical models of the hydraulic system are used, then controller synthesis is simplified, but model accuracy is reduced due to incomplete or difficult-to-determine information
Solution Approach 1:
The patent replaces traditional mechanical model-based identification with data-driven computer-based model identification that automatically processes sensor measurements to identify system behavior, eliminating the need for manual model parameter determination
Solution Approach 2:
The system uses feedback from sensor measurements during the measurement routine to continuously refine the identified system behavior and adjust controller parameters, ensuring accuracy without requiring complete prior system knowledge
3Quantity of substance
If only a few sensors are installed in the hydraulic system, then cost is reduced, but precise control becomes more difficult due to incomplete measurement data
Solution Approach 1:
The identified system behavior model serves multiple functions: it characterizes system dynamics for control synthesis, compensates for missing sensor data through prediction, and adapts to changing system conditions, making the system effective with minimal sensors
4Adaptability or versatility
If electronic controllers are made adaptable to changing conditions, then control quality improves, but device complexity increases
Solution Approach 1:
The controller parameters are synthesized to be dynamically adaptable to changing system conditions by using the identified system behavior model that captures non-linearities and time-varying characteristics, allowing the controller to adjust to different operating points without increasing physical complexity
Data Source
AI summary
In a method for the automated, measurement data-based configuration of an electronic controller for a hydraulic system, a predefined measurement routine is performed on the hydraulic system, during which measurement data of measurement parameters of the hydraulic system are automatically acquired. This measurement data is used to train a computer-based model structure, i.e. to automatically identify the behavior of the hydraulic system. On the basis of system equations automatically extracted from the computer-based model structure, an electronic controller is automatically synthesized and then automatically embedded in a control unit of the hydraulic system in order to control at least one control variable, such as a pressure, a volume flow, a position or a displacement, in the hydraulic system. The automated steps of the method can be performed by an external device, which is connected to the hydraulic system via a data communication interface.