Hydraulic Servo Valve Calibration Data for Auto-Tuned Position Control
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Solution Overview
Problem
Hydraulic servo valves and servo amplifiers face challenges in adjustment and integration due to individual differences in hydraulic characteristics and non-linear flow rate characteristics, requiring cumbersome re-adjustment and replacement, especially in harsh environments, which complicates manufacturing and field deployment.
Innovation Solution
Incorporating a position sensor with a storage section that holds calibration and flow rate characteristics information, allowing a servo amplifier to read and apply this data for origin correction and optimization, eliminating the need for manual adjustments and enabling convenient integration and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment and calibration are performed for each hydraulic servo valve, then measurement precision and manufacturing precision are improved, but adjustment time and device complexity increase
Solution Approach 1:
The patent applies preliminary action by pre-measuring and storing the actual flow rate characteristics of each hydraulic servo valve in a storage unit during manufacturing. This allows the servo amplifier to automatically retrieve and use these pre-calibrated characteristics data during operation, eliminating the need for manual adjustment and calibration at the installation site, thus reducing adjustment time while maintaining manufacturing precision.
2Measurement precision
If hydraulic servo valves are replaced due to characteristic deviations, then measurement precision is maintained, but productivity decreases and loss of time increases
Solution Approach 1:
The patent applies parameter changes by allowing the servo amplifier to dynamically adapt to different hydraulic servo valves through automatic retrieval of characteristics data stored in the storage unit. Each valve's unique flow rate characteristics are stored as parameters, and the servo amplifier adjusts its control parameters based on the retrieved data, maintaining control accuracy without requiring valve replacement.
3Measurement precision
If non-linear flow rate characteristics are compensated through manual adjustment, then measurement precision is improved, but device complexity and ease of operation worsen
Solution Approach 1:
The patent applies self-service by enabling the servo amplifier to automatically retrieve the hydraulic servo valve's flow rate characteristics from the storage unit and perform self-adjustment without manual intervention. The system automatically compensates for non-linear characteristics by using the pre-stored characteristics data, eliminating the need for operators to perform complex manual adjustments while maintaining flow rate control accuracy.
4Ease of operation
If characteristic data is stored and retrieved automatically, then ease of operation and productivity are improved, but device complexity increases
Solution Approach 1:
The patent applies merging by integrating the storage unit into the hydraulic servo valve assembly and establishing automatic communication between the storage unit and servo amplifier. This combines multiple functions (data storage, data retrieval, automatic adjustment) into a unified system, improving ease of operation and productivity while managing device complexity through functional integration rather than separate components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution simplifies the adjustment process in manufacturing and field deployment, ensuring accurate operation and reducing the need for frequent servo amplifier replacements by allowing the servo amplifier to read and apply stored characteristics information, enhancing convenience and reliability.
Implementation Method 1
Such hydraulic servo valves integrally include a differential transformer, in many cases an LVDT (Linear Variable Differential Transformer), as a position sensor for performing feedback control of a spool position
Data Source
AI summary
A hydraulic device with the position sensor feedback-controlled by a servo amplifier on the basis of a deviation between a command value of a command signal and a position sensing value from a position sensor includes: a computation processing section that outputs the position sensing value as a sensing signal; a communication device that transmits the sensing signal to the servo amplifier, and receives a signal from the servo amplifier; and a storage section storing characteristics information of the hydraulic device to be read via the communication device. The characteristics information at least includes: calibration information which is measured and acquired in advance in a test stand in a manufacturing process of the hydraulic device, and includes a position sensing value from the position sensor and a characteristics value of the hydraulic device, associated with each other; and flow rate characteristics information including a flow rate of the hydraulic device.