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<p>Condition Monitoring is an area that has seen substantial growth in the last few decades. The purpose for implementing condition monitoring in industry is to increase productivity, decrease maintenance costs and increase safety. Therefore, condition monitoring can be used not only for planning maintenance but also for allowing the selection of the most efficient equipment to minimize operating costs. </p><p>Hydraulic systems are widely used in industry, aerospace and agriculture and are becoming more complex in construction and in function. Reliability of the systems must be supported by an efficient maintenance scheme. Due to component wear or failure, some system parameters may change causing abnormal behaviour in each component or in the overall circuit. Research in this area has been substantial, and includes specialized studies on artificial fault simulation at the University of Saskatchewan. In this research, an axial pump was the focus of the study. In an axial piston pump, wear between the various faces of components can occur in many parts of the unit. As a consequence, leakage can occur in locations such as between the valve plate and barrel, the drive shaft and oil wiper, the control piston and piston guide, and the swash plate and slippers. In this study, wear (and hence leakage) between the pistons and cylinder bores in the barrel was of interest. Researchers at the University of Saskatchewan, as well as at other research institutions, have been involved in studies to detect wear in pumps using a variety of condition monitoring algorithms. However, to verify the reliability and indeed, limitations of some of the approaches, it is necessary to test the algorithms on systems with real leakage. To introduce actual wear in the piston of pumps can be very difficult and very expensive. Hence, introducing piston wear in an artificial manner would be of great benefit in the evaluation of various condition monitoring techniques.</p><p>Since leakage is a direct consequence of piston wear, it is logical to conclude that varying the leakage in some prescribed manner can be used to artificially simulate wear. A prime concern, therefore, is to be able to precisely understand the dynamic relationships between the wear and leakage and the effect it has on the output flow or pressure waveform from the pump.</p><p>Introducing an artificial leakage to simulate the wear of pistons is a complex task. The creation of an artificial leakage path was not simply a process of providing a resistive short to the tank at the outlet of the pump port as was done in other studies. The objective was to create a leakage environment that would simulate leakage from a single piston (or combination of several pistons thereof). The complexity of the flow and pressure ripple waveforms (which various condition monitoring algorithms did require) was such that a more comprehensive leakage behaviour had to be modeled and experimentally created. A pressure control servo valve with a very high frequency response was employed to divert the flow from the pump outlet with a prescribed waveform directly to the tank to simulate the piston leakage from the high pressure discharge chamber to the pump case drain chamber as the simulated worn piston made contact with the high pressure chamber. The control algorithm could mimic the action of a single worn piston at various degrees of wear. The experimental results indicated that the experimental system could successfully introduce artificial leakage into the pump which was quite consistent with a unit with a real worn piston. Comparisons of the pressure ripples from an actual faulty pump (worn piston) and the artificial faulty pump (artificial leakage) are presented.</p>

<p>Condition Monitoring is an area that has seen substantial growth in the last few decades. The purpose for implementing condition monitoring in industry is to increase productivity, decrease maintenance costs and increase safety. Therefore, condition monitoring can be used not only for planning maintenance but also for allowing the selection of the most efficient equipment to minimize operating costs. </p><p>Hydraulic systems are widely used in industry, aerospace and agriculture and are becoming more complex in construction and in function. Reliability of the systems must be supported by an efficient maintenance scheme. Due to component wear or failure, some system parameters may change causing abnormal behaviour in each component or in the overall circuit. Research in this area has been substantial, and includes specialized studies on artificial fault simulation at the University of Saskatchewan. In this research, an axial pump was the focus of the study. In an axial piston pump, wear between the various faces of components can occur in many parts of the unit. As a consequence, leakage can occur in locations such as between the valve plate and barrel, the drive shaft and oil wiper, the control piston and piston guide, and the swash plate and slippers. In this study, wear (and hence leakage) between the pistons and cylinder bores in the barrel was of interest. Researchers at the University of Saskatchewan, as well as at other research institutions, have been involved in studies to detect wear in pumps using a variety of condition monitoring algorithms. However, to verify the reliability and indeed, limitations of some of the approaches, it is necessary to test the algorithms on systems with real leakage. To introduce actual wear in the piston of pumps can be very difficult and very expensive. Hence, introducing piston wear in an artificial manner would be of great benefit in the evaluation of various condition monitoring techniques.</p><p>Since leakage is a direct consequence of piston wear, it is logical to conclude that varying the leakage in some prescribed manner can be used to artificially simulate wear. A prime concern, therefore, is to be able to precisely understand the dynamic relationships between the wear and leakage and the effect it has on the output flow or pressure waveform from the pump.</p><p>Introducing an artificial leakage to simulate the wear of pistons is a complex task. The creation of an artificial leakage path was not simply a process of providing a resistive short to the tank at the outlet of the pump port as was done in other studies. The objective was to create a leakage environment that would simulate leakage from a single piston (or combination of several pistons thereof). The complexity of the flow and pressure ripple waveforms (which various condition monitoring algorithms did require) was such that a more comprehensive leakage behaviour had to be modeled and experimentally created. A pressure control servo valve with a very high frequency response was employed to divert the flow from the pump outlet with a prescribed waveform directly to the tank to simulate the piston leakage from the high pressure discharge chamber to the pump case drain chamber as the simulated worn piston made contact with the high pressure chamber. The control algorithm could mimic the action of a single worn piston at various degrees of wear. The experimental results indicated that the experimental system could successfully introduce artificial leakage into the pump which was quite consistent with a unit with a real worn piston. Comparisons of the pressure ripples from an actual faulty pump (worn piston) and the artificial faulty pump (artificial leakage) are presented.</p>

The theoretical stability analysis of mold level control system for slab continuous casting machine is presented in this thesis. In the procedure of analyzing the stability of the mold level control system, the PLC program written for the control system is studied first in order to obtain the mathematical model of a PID controller. Then the mathematical models of servo-amplifier, servo-valve, electro hydraulic system to the output of mold level are established. A simulative control system using Matlab software is constructed in accordance with these mathematical models so that not only the results of stability analysis can be verified but also the dynamic response of controlled system can be studied. Finally, the effects of some potential disturbance on system¡¦s dynamics, stability, and control accuracy are also analyzed.

Elevation axis model of a barrel stabilization system is constructed. The nonlinearities which are considered in the model are orifice flow characteristics, coulomb friction, hard-stop limits, kinematics of the system and unbalance on the barrel. A Simulink&reg / model for the servo valve, actuation system and barrel is constructed. Servo valve identification is made via the actual test data. Compressibility of the hydraulic fluid is taken into consideration while modeling the actuation system. Friction model is simulated for different cases. Controller of the system is constructed by two PIDs, one for each of the velocity and the position loops. Velocity feed forward can reduce the time to make a quick move by the system. The disturbance is evaluated from a given road profile and disturbance feed forward is applied to the system.

An industrial control valve has been designed by Eaton (AxisPro® valve). The servo performance valve has onboard electronics that features external and internal sensor interfaces, advanced control modes and network capability. Advanced control modes are implement in the valves firmware. With the help of the white space it is possilbe to execute custom code directly on the valve that interact with these controls. Small OEM applications, like rubber moulding machines, benefit from the comination of build in controls and custom code, to provide adaptations for their special machines.

Orientador: Nelson Luis Cappelli / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Agricola / Made available in DSpace on 2018-08-05T14:31:39Z (GMT). No. of bitstreams: 1 Johann_AndreLuiz_M.pdf: 4693125 bytes, checksum: d66ad55f78541f74570f40b7bebc1591 (MD5) Previous issue date: 2004 / Resumo: Este trabalho teve como objetivo projetar, construir e avaliar uma servoválvula dosadora para a aplicação de fertilizantes líquidos a taxas variáveis, bem como conceber um sistema com capacidade para formulação e dosagem no qual a válvula poderá operar. Foi concebido um sistema capaz de trabalhar com três formulações de concentrados simultaneamente, utilizando-se três circuitos hidráulicos independentes. Cada um destes circuitos deve ser dotado de uma bomba centrífuga capaz de fornecer pressão e vazão à linha hidráulica para possibilitar a operação de uma válvula dosadora controlada eletricamente. Uma bancada de testes foi desenvolvida para a realização de ensaios experimentais, cuja finalidade foi a de avaliar o desempenho da servo-válvula. Esta bancada representa um circuito simplificado do sistema concebido. A válvula dosadora pode ser considerada o elemento mais importante do sistema de aplicação de fertilizantes concebido. A proposta inicial contemplava a utilização de válvulas com acionamento por solenóide, por meio de um sinal PWM, no entanto, esta alternativa não se mostrou viável tecnicamente. Desta forma, foi necessário o desenvolvimento de uma nova válvula para atender aos requisitos de operação do sistema. A válvula dosadora desenvolvida é dotada de um acionamento mecânico feito por meio de um servo-motor. O controle do fluxo é feito por meio de um obturador cônico. A válvula foi avaliada quanto ao seu comportamento, apresentando boa repetitividade, presença de histerese e resposta tipicamente quadrática. O efeito da histerese póde ser evitado efetuando-se o ajuste da válvula somente em operações de abertura ou de fechamento e a resposta quadrática não representa um problema. Devido a um problema de inflexão na faixa inicial da curva de fechamento da válvula, esta foi restringida para valores acima de 25%. Depois de avaliada e aprovada a válvula, foram realizados ensaios visando à obtenção de um modelo matemático experimental do comportamento da vazão em termos do seu percentual de abertura e pressão de trabalho. O método experimental empregado foi o planejamento multifatorial 2k. O critério de avaliação do modelo incluía o cálculo do seu coeficiente de determinação R2, uma análise de variância e uma análise de resíduos. Primeiramente foi obtido um modelo matemático linear, que apresentou um bom ajuste segundo o coeficiente de determinação, bem como apresentou uma boa significância estatística, segundo a análise de variância. No entanto, os resíduos do modelo linear não se mostraram bons, apresentando tendência. Partiu-se então para a obtenção de um modelo matemático quadrático que também apresentou um bom ajuste e uma boa significância estatística, diferenciando-se pelo fato de ter sido minimizada a tendência observada nos seus resíduos em relação ao modelo linear. O modelo quadrático inicialmente possuía a característica de superestimar os valores de vazão, a qual foi eliminada por meio de um ajuste fino do termo constante do modelo. A servo-valvula desenvolvida, bem como o modelo experimental obtido, atenderam ao objetivo deste trabalho. O protótipo operou de forma satisfatória com o fluído de trabalho utilizado e o modelo matemático descreveu adequadamente o comportamento da válvula dosadora / Abstract: This work had as aim to project, to build and to evaluate a flow control servo-valve for liquid fertilizer application in variable rates, as well as to conceive a system with capacity for formulation and dosage in which the valve can operate. It was conceived a system capable to work with three concentrate formulations simultaneously, using three independent hydraulic circuits. Each one of these circuits should be endowed with a centrifuge pump capable to supply pressure and flow to the hydraulic line to make possible the flow control valve operation controlled electrically. A workbench was built for the experimental rehearses accomplishment, whose purpose was of evaluating its acting. This workbench represents a conceived system simplified circuit. A flow control valve can be considerate the most important element of the developed fertilizer application system. The initial proposal contemplated the use of solenoid drived valves by means of a PWM (Pulse Wave Modulation) sign; however this alternative was not shown technically viable. This way, it was necessary the new valve development to assist to the operation system requirements. The developed flow control valve mechanical driving is made through a servomotor. The flow control is made by means of a conical obturator. The valve behavior was evaluated, presenting good repetibility, presence of hysteresis and an answer typically quadratic. The hysteresis effect can be avoided being made the valve adjustment only in opening or closing operations. The quadratic answer does not represent a problem. Due to inflection problem, in the initial rate of the valve closing curve, this was restricted for values above 25%. After the valve has been evaluated and approved, tests were accomplished seeking the obtaining of a flow behavior experimental mathematical model in terms of its opening percentile and work pressure. The used experimental method was the 2k multifactor planning. The model evaluation criterion included the R2 determination coefficient calculation, a variance analysis and a residues analysis. Firstly it was obtained a linear mathematical model that presented a good adjustment according to the determination coefficient. It also presented a good statistical significance in agreement with the variance analysis. However, the linear model residues were not shown good, presenting tendency. Then, it was followed the quadratic mathematical model obtention. That also presented a good adjustment and a good statistical significance, differing for the fact of the observed tendency in its residues having been minimized in relation to the linear model. The quadratic model initially had the characteristic of overestimating the flow values, which was eliminated by means of a model constant term fine adjustment. The developed servo-valve and the obtained experimental model assisted to the aim of this work. The prototype of this work operated in a satisfactory way with the fluid work used. The mathematical model described the flow control valve behavior appropriately / Mestrado / Maquinas Agricolas / Mestre em Engenharia Agrícola

An industrial control valve has been designed by Eaton (AxisPro® valve). The servo performance valve has onboard electronics that features external and internal sensor interfaces, advanced control modes and network capability. Advanced control modes are implement in the valves firmware. With the help of the white space it is possilbe to execute custom code directly on the valve that interact with these controls. Small OEM applications, like rubber moulding machines, benefit from the comination of build in controls and custom code, to provide adaptations for their special machines.

Servo valves are used in a broad variety of flow modulation applications. In the field of aerospace, servo valves are used in aero engines to meter fuel flow. The existing valves are labour intensive to manufacture and highly optimised such that to achieve improvements in performance requires a novel design. This research investigates smart material actuators and valve concepts. Specifically, a prototype pilot stage nozzle flapper valve is developed for the purpose of actuating a main stage spool. The typical nozzle flapper type servo valve uses a torque motor to actuate the flapper. In this research project, the torque motor has been substituted for two piezoelectric ring bender actuators. A novel mounting mechanism has been developed to secure the ring benders within the valve. Analytical and finite element models have been made to understand the displacement mechanism of a ring bender and the effects of the mount on the displacement and force from a ring bender, and the results were compared with experiment. The mounting stiffness at the inner and outer edges was found to decrease the displacement of the ring bender and it was found that the stiffness of the mount at the outer edge has a greater negative effect on displacement than the stiffness of the mount at the inner edge. The displacement of a ring bender was tested across the operational temperature range of an aero engine. It was found that the displacement of the ring bender is reduced at low temperatures and increases at high temperature. The variation of stiffness of the elastomeric mount was also tested with temperature and it was found that the displacement of a ring bender is significantly reduced when the mounting elastomer approaches its glass transition temperature. A prototype valve was built to test the pressures and flows that could be achieved at two control ports by using a ring bender as actuator. A single ring bender and two ring benders, mounted in tandem to provide redundancy, have been tested. An analytical model was developed and the predictions are compared with experimental results for pressures and flow. The full stroke of the valve was 300m when mounted and reduced to 150m when mounted in tandem with an inactive ring bender. The hysteresis of the valve is +/-10%. The pressures and flow at and between the control ports of the valve are consistent with the predictions.