The pitch trim actuator is a hydraulic powered electro-mechanical flight control device of UH-60 helicopters which converts a mechanical input and an electrical command into a mechanical output with trim detent capabilities. In this thesis study, pitch trim actuator is investigated and a mathematical model is developed. From these mathematical equations, the actuator is modeled in MATLAB Simulink environment. While constructing the mathematical model, pressure losses in hydraulic transmission lines and compressibility of hydraulic oil are considered. To achieve a more realistic model for valve torque motor, particular tests are carried out and the torque motor current gain and the stiffness of torque motor flexure tube and the flapper displacement are obtained. Experimental data to verify the Simulink model is acquired with KAM-500 data acquisition system. A test fixture is designed for acquiring the experimental data. This test fixture can also be used to test the pitch trim actuator during depot level maintenance and overhaul. To verify the consistency of Simulink model, acquired experimental data is implemented in Simulink environment. The output of Simulink model simulation and the experimental data are compared. The results of comparison show that the model is good enough to simulate the steady state behavior of the actuator.

The non-linear model of pneumatic acting system, consisting of proportional directional control valve and symmetric rodless pneumatic cylinder is developed and investigated in this paper. This model enables to evaluate influence of essential nonlinearities concerned with working characteristics of airflow regulating valves and pneumatic cylinders on dynamics of the system. The modeling results of pneumatic acting system under several initial working conditions are presented and discussed in this article. The model reference based adaptive control method of force regulation in electro-pneumatic servo system is proposed and investigated in this paper to. This method allows eliminating of influence of nonlinearities of pneumatic cylinder and directional control valve on behavior of force regulation system. Therefore controllers of higher hierarchy level such as velocity and position controllers can be designed using conventional methods based on quantitative optimum. The modeling results of investigated system are presented in the paper.

O elemento final de controle mais usado nas malhas de processo na indústria é a válvula de controle. Portanto, é necessário assegurar que ela possua o melhor desempenho possível, a fim de assegurar um funcionamento satisfatório da malha de controle. Devido ao desgaste natural das partes móveis e o ressecamento das gaxetas, as válvulas apresentam atrito que insere oscilações na abertura da válvula e devido a seu comportamento não linear que diminui a eficiência do controle. A presença de oscilações nas malhas de controle aumenta a variabilidade das variáveis de processo, o desgaste dos componentes e o consumo de energia, além de provocar o desperdício de materiais. Por isto, no presente trabalho são estudados e implementados diferentes compensadores de atrito existentes na literatura, visando reduzir o efeito do atrito nas válvulas e, por sua vez as oscilações na variável do processo. Estes métodos são aplicados na Planta Piloto de Neutralização de pH do Laboratório de Controle de Processos Industriais (LCPI). O processo de neutralização de pH é não-linear e apresenta características variantes no tempo, as quais tornam mais complexo o controle do processo. Inicialmente foi feita a implementação dos compensadores em um software acadêmico (MATLAB®), devido à familiaridade que se tem com ele, o que facilitou um melhor entendimento dos métodos de compensação junto com o controlador PID no processo. Em uma segunda etapa, a fim de trazer os estudos a um ambiente mais prático, foram implementados os algoritmos de compensação de atrito em um sistema de controle industrial (ABB®). Nos dois casos se realizaram testes em modo servo e regulatório e se avaliaram os resultados obtidos usando o índice ITAE (Integral Time Absolute Error). Os resultados evidenciam que os compensadores conseguem diminuir a variabilidade na válvula de controle, sendo que o compensador CR2 apresentou o melhor desempenho para o modo servo e regulatório. / The most used final control element in process loops in the industry is the control valve. It must ensure that it has the best possible performance in order to guarantee a satisfactory operation of the control loop. Due of the natural wear of moving parts and drying gaskets, valves exhibit friction. This friction inserts oscillations in the valve opening and due to its non-linear behavior; this causes the efficiency to decrease. The presence of oscillations in the control loop increases the variability of the process variables, the component wear, energy consumption and cause a waste of materials. Therefore, in this work we studied and implemented different friction compensation methods that exist in literature, in order to reduce the effect of friction on the valves and in turn the oscillations in the process variable. These methods are applied in the Pilot Plant Neutralization pH of Industrial Process Control Laboratory (LCPI), the pH neutralization process is nonlinear and presents time-varying characteristics, these characteristics become the control process more complex. Initially, it was made the implementation of compensation methods in academic software (MATLAB®), due to the familiarity that already exist with it, which facilitated a better comprehension of the compensation methods with the PID controller in the process. In a second step, in order to bring the study to a more practical environment, the friction compensation algorithms were implemented in an industrial control system (ABB®). In both cases were performed tests inn servo and regulatory mode, and evaluated the results using the ITAE index (Integral Time Absolute Error). The results show that in general terms that the compensating methods showing a very satisfactory performance, with the compensator CR2 showed the best performance for the servo and regulatory mode.

The aim of this diploma thesis is reconstruction of an existing heat recuperative station. The reason is morally and physically survive to the device. Introduction to focus on the heat exchangers. The next section is devoted to the actual design of technological devices exchange stations, which represents the heat exchangers, pumps, control valves, safety devices, etc. The final phase is an economic analysis aimed at determining return on investment.

This project presents an investigation if natural braking characteristics could be achieved on an open-loop hydraulic transmission without a brake valve. The goal with the simplified system was to utilize the directional control valve to achieve similar functionality as the brake valve does in the conventional system. If the solution functions properly, it will reduce costs, save time and simplify the conventional system which uses a dedicated brake valve. With a simulation model and practical experiments, the simplified system was thoroughly studied and tested. Two different concepts of how to control the directional control valve were developed, named Fixed Control and Torque Control. The Fixed Control concept has a predetermined de-stroking profile which is not affected by other system signals other than the gas pedal signal. The Torque Control concept uses in addition to the gas pedal signal, pressure sensors over the motors to maintain a constant braking torque. Both developed concepts were able to produce natural braking characteristics. However, the Torque Control concept performed better at different circumstances. Respective concept can be tuned further for improvements, but in the scope of this project the goal was accomplished. Utilizing the directional control valve to achieve a hydraulic brake function, has potential to be a solutionfor heavy mobile machinery in near future. However, further research and testing are required to be conducted on other heavy mobile machinery which have greater top speeds and load capabilities than the machinery used in this project.

The Diploma Thesis presents a draft of designated automatic apparatus for cutting out and assembling pads for pressure control valve (DRV2). The theoretical chapter of the Thesis contains selected findings from theory and technology for material cutting. The next chapter contains design solutions for a designated apparatus for cutting and assembling pressure control valves. The pads are etched from 0,08 mm steel plates X2CrNi Mol7-12-2. The shape of the pads is etched on a 35mm-wide belt that is wound up onto a drum. The draft of this new technological facility has been elaborated in accordance with the most suitable technological variant. The cutting tool is made of steel 19 437 that is thermally processed at HRC 62-4. Estimated annual volume of production series is 2 mil. pcs. The cutting and assembly processes are executed with the aid of this designated automatic apparatus.

Electro-hydraulic proportional flow valves are widely used in hydraulic industry. There are several different structures and working principles. However, flow valves based on the existing principles usually have some shortcomings such as the complexity of the system and additional energy losses. A concept for a two-stage poppet flow valve with pilot pressure drop – pilot spool opening compensation is presented, and the linear relationship between the pilot stage and main stage, the semi-empirical flow equation are used in the electronic flow controller. To achieve the accurate control of the outlet flow, the actual input voltage of the pilot spool valve is regulated according to the actual pilot pressure drop, the desired flow rate and the given input voltage. The results show that the pilot pressure drop – pilot spool opening compensation method is feasible, and the proposed proportional flow control valve with this compensation method has a good static and dynamic performance.

Other than mobile hydraulics and high voltage switchgears, Bucher Hydraulics is also involved in the less-known area of hydraulic lifts. In fact, Bucher Hydraulics did invent the electronically controlled lift valve in the 1970s. Since then, Bucher Hydraulics developed a wide line of products for hydraulic elevators, such as valves and power units. In 2012, this valve family included various sizes, pressure ranges, systems with constant motor speeds, inverter-driven motors, energy-efficient solutions with hydraulic counterweight, as well as customized solutions. As the common principle, all these solutions apply an electronic closed-loop control that uses a volumetric flow sensor and a proportional actuator. Since 2012, Bucher Hydraulics is substituting this valve family with a new generation, the iValve. Every iValve uses several self-teaching algorithms to adapt to its environment. Their on-board and cabinet electronics control solenoid currents and measure flow, pressure, and temperature. These features enable the iValve to self-monitor, to adapt to operating parameters, and to analyze and log information about itself and the attached system. This report on a highly specialized product is meant to provide inspiring insights.

In this paper numerical flow calculations with respect to the annular gaps with added radial grooves normaly used on the spools of directional control valves were carried out. The impact of various annular gap geometries and radial grooves during variable pressure conditions, and while using different hydraulic fluids, on the flows through annular gaps were investigated for different flow regimes. Samples with different geometries and numbers of radial groves on the spool of the directional control valve were also made for the purpose of carrying out flow measurements. The two different hydraulic fluids that were used in the numerical simulations and for the flow measurements were a hydraulic mineral oil and tap water. The results of the numerical calculations for the different models of the radial grooves with axially symmetric geometries show their impact on the internal leakage with respect to three different regimes of flow. The results of the numerical calculations based on the use of a hydraulic oil show a trend that was established by the experimental investigation.

This diploma thesis deals with the design of control algorithm for hydraulic directional control valves of a zero-emission mini excavator. Zero emission excavator have same parameters as diesel engine powered version of it. To solve this problem simulations were done for hydraulics and control algorithm of this machine. To find right parameters of simulation models, experiments have been done. There were also proposed some methods to obtain the right set of parameters. The result of this diploma thesis is control algorithm for directional control valves of this very unique mini excavator that doesn't have any competitor (in terms of control algorithm). Set of parameters was also tested during experiments.