Fault simulator for proportional solenoid valves

Proportional Solenoid Valves (PSV) have been successfully used in the hydraulic industry for many years due to the benefits associated with higher accuracy compared to on/off solenoid valves, and the robustness and cost compared to servo valves. Because the PSV plays an important role in the performance of a hydraulic system, a technique commonly referred to as Condition Monitoring Scheme (CMS) has been used extensively to monitor the progress of faults in the PSV. But before any CMS can be implemented on a system, it needs to be thoroughly tested for its reliability of fault detection since, a failure of the CMS to detect any potential fault can be economically disastrous, and dangerous in terms of the safety of personnel. The motivation of this research was to develop a fault simulator which could reliably and repeatedly induce user defined faults in the PSV and thereby aid in testing the efficacy of the CMS for monitoring such simulated faults.Industry research has revealed that the most common mode of failure in spool valves is an increase in the friction between the spool and valve, due to wear, contamination and dirt, which renders the valve inoperable. In this research, a non-destructive fault simulator was developed which induced artificial friction faults in the PSV. The PSV consisted of two solenoids on the opposite sides of the valve spool by virtue of which, bi-directional position control could be achieved. The PSV with the spool and one of the solenoids was used as the system in which the faults were simulated, and the second solenoid was used an a fault simulator for inducing the desired friction characteristics in the system. The friction characteristics induced in the valve were similar to those in the classical friction curve, i.e., stiction at low velocities and Coulomb and viscous friction at higher velocities. By employing a closed loop position control scheme, one of the solenoids was used to generate a linearly increasing velocity profile by virtue of which the desired friction characteristics could be induced in different velocity regimes. The other solenoid was used to generate the desired friction force. A closed loop force control strategy, which used the feedback from a force transducer, allowed for the accurate control of the friction characteristics. stiction was induced at low velocities by passing the required current in both the solenoids that resulted in no net force on the valve spool. Due to the absence of any driving force the spool was stalled at the desired location, thus achieving the same effect of stiction at low velocities. The coulomb and viscous friction were induced at higher velocities by employing an algorithm which was a function of the spool velocity. Different magnitudes of static, coulomb and viscous friction were induced to achieve the friction characteristics represented by the classical friction curve. Since the change in force characteristics of the valve results in a corresponding change in the current drawn by the position control solenoid, a rudimentary CMS for monitoring the current characteristics is presented. Based on the experimental results and validation using the CMS it was concluded that the fault simulator was able to accurately produce the desired frictional loading on the valve spool and was able to do so with a high degree of repeatability. Proportional Solenoid Valves (PSV) have been successfully used in the hydraulic industry for many years due to the benefits associated with higher accuracy compared to on/off solenoid valves, and the robustness and cost compared to servo valves. Because the PSV plays an important role in the performance of a hydraulic system, a technique commonly referred to as Condition Monitoring Scheme (CMS) has been used extensively to monitor the progress of faults in the PSV. But before any CMS can be implemented on a system, it needs to be thoroughly tested for its reliability of fault detection since, a failure of the CMS to detect any potential fault can be economically disastrous, and dangerous in terms of the safety of personnel. The motivation of this research was to develop a fault simulator which could reliably and repeatedly induce user defined faults in the PSV and thereby aid in testing the efficacy of the CMS for monitoring such simulated faults. Industry research has revealed that the most common mode of failure in spool valves is an increase in the friction between the spool and valve, due to wear, contamination and dirt, which renders the valve inoperable. In this research, a non-destructive fault simulator was developed which induced artificial friction faults in the PSV. The PSV consisted of two solenoids on the opposite sides of the valve spool by virtue of which, bi-directional position control could be achieved.The PSV with the spool and one of the solenoids was used as the system in which the faults were simulated, and the second solenoid was used an a fault simulator for inducing the desired friction characteristics in the system. The friction characteristics induced in the valve were similar to those in the classical friction curve, i.e., stiction at low velocities and Coulomb and viscous friction at higher velocities. By employing a closed loop position control scheme, one of the solenoids was used to generate a linearly increasing velocity profile by virtue of which the desired friction characteristics could be induced in different velocity regimes. The other solenoid was used to generate the desired friction force. A closed loop force control strategy, which used the feedback from a force transducer, allowed for the accurate control of the friction characteristics. stiction was induced at low velocities by passing the required current in both the solenoids that resulted in no net force on the valve spool. Due to the absence of any driving force the spool was stalled at the desired location, thus achieving the same effect of stiction at low velocities. The coulomb and viscous friction were induced at higher velocities by employing an algorithm which was a function of the spool velocity. Different magnitudes of static, coulomb and viscous friction were induced to achieve the friction characteristics represented by the classical friction curve. Since the change in force characteristics of the valve results in a corresponding change in the current drawn by the position control solenoid, a rudimentary CMS for monitoring the current characteristics is presented. Based on the experimental results and validation using the CMS it was concluded that the fault simulator was able to accurately produce the desired frictional loading on the valve spool and was able to do so with a high degree of repeatability

Discrete-time sliding mode control of high precision linear drive using frictional model

The paper deals with high precision motion control of linear drive system. The accuracy and behavior of the linear drive system are highly affected by the non-linear frictional component compromising of stiction, viscous and stribeck effect present in the system especially in the vicinity of zero velocity. In order to achieve the high accuracy and motion it is mandatory to drive our system with low velocity resulting in many non linear phenomena like tracking error, limit cycles and undesired stick-slip motion etc. This paper discuss the design and implementation of discrete time sliding mode control along with the implementation of dynamic frictional model in order to estimate and compensate the disturbance arising due to frictional component. Experimental results are presented to illustrate the effectiveness and achievable control performance of the proposed scheme

Elasto-plastic friction model: contact compliance and stiction

The presliding displacement and stiction properties of friction models are investigated. It is found that existing single-state-variable friction models possess either stiction or presliding displacement. Next, those models with continuous states are interpreted as examples of Prandlt’s elasto-plastic material model. A class of general one-state models is derived that is stable, dissipative and exhibits both stiction and presliding displacement.

Canards in stiction: on solutions of a friction oscillator by regularization

We study the solutions of a friction oscillator subject to stiction. This discontinuous model is non-Filippov, and the concept of Filippov solution cannot be used. Furthermore some Carath\'eodory solutions are unphysical. Therefore we introduce the concept of stiction solutions: these are the Carath\'eodory solutions that are physically relevant, i.e. the ones that follow the stiction law. However, we find that some of the stiction solutions are forward non-unique in subregions of the slip onset. We call these solutions singular, in contrast to the regular stiction solutions that are forward unique. In order to further the understanding of the non-unique dynamics, we introduce a regularization of the model. This gives a singularly perturbed problem that captures the main features of the original discontinuous problem. We identify a repelling slow manifold that separates the forward slipping to forward sticking solutions, leading to a high sensitivity to the initial conditions. On this slow manifold we find canard trajectories, that have the physical interpretation of delaying the slip onset. We show with numerics that the regularized problem has a family of periodic orbits interacting with the canards. We observe that this family has a saddle stability and that it connects, in the rigid body limit, the two regular, slip-stick branches of the discontinuous problem, that were otherwise disconnected.Comment: Submitted to: SIADS. 28 pages, 12 figure

Hidden dynamics in models of discontinuity and switching

AbstractSharp switches in behaviour, like impacts, stick–slip motion, or electrical relays, can be modelled by differential equations with discontinuities. A discontinuity approximates fine details of a switching process that lie beyond a bulk empirical model. The theory of piecewise-smooth dynamics describes what happens assuming we can solve the system of equations across its discontinuity. What this typically neglects is that effects which are vanishingly small outside the discontinuity can have an arbitrarily large effect at the discontinuity itself. Here we show that such behaviour can be incorporated within the standard theory through nonlinear terms, and these introduce multiple sliding modes. We show that the nonlinear terms persist in more precise models, for example when the discontinuity is smoothed out. The nonlinear sliding can be eliminated, however, if the model contains an irremovable level of unknown error, which provides a criterion for systems to obey the standard Filippov laws for sliding dynamics at a discontinuity

Nonlinear Friction Model for Passive Suspension System Identification and Effectiveness

To achieve a high level of performance, frictional effects have to be addressed by considering an accurate friction model, such that the resulting model faithfully simulates all observed types of friction behaviour. A nonlinear friction model is developed based on observed measurement results and dynamic system analysis. The model includes a stiction effect, a linear term (viscous friction), a nonlinear term (Coulomb friction) and an extra component at low velocities (Stribeck effect). During acceleration, the magnitude of the frictional force at just beyond zero velocity decreases due to the Stribeck effect, which means the influence of friction reduces from direct contact with bearings and body into the mixed lubrication mode at low velocity. This could be due to lubricant film behaviour. In respect of acceleration and deceleration when the direction changes for the mass body, friction almost depends on this direction, while the static frictional force exhibits springlike characteristics. However, friction is not determined by current velocity alone, it also depends on the history of the relative wheel and body velocities and movements, which are responsible for friction hysteresis behaviour

Development of a Simulink® toolbox for friction control design and compensation

This paper focuses on the development of a MATLAB/Simulink® library for servo-systems with friction as a part of a new simulation platform dedicated to model, analysis and control design of friction. It is well known that friction is a very important process for the control engineering both for high-precision servo – mechanisms and simple pneumatic and hydraulic systems. Highly nonlinear process, friction may result in steady state errors, limit cycles and poor performance. It is therefore important for control engineering to understand friction phenomena and to know how to deal with them. Moreover, a reliable library of friction models that captures the friction behavior provides an important tool in order to investigate by analysis and simulation the properties of friction that are relevant to control design

Artificial intelligent based friction modelling and compensation in motion control system

The interest in the study of friction in control engineering has been driven by the need for 10 precise motion control in most of industrial applications such as machine tools, robot 11 systems, semiconductor manufacturing systems and Mechatronics systems. Friction has 12 been experimentally shown to be a major factor in performance degradation in various 13 control tasks. Among the prominent effects of friction in motion control are: steady state 14 error to a reference command, slow response, periodic process of sticking and sliding (stick-15 slip) motion, as well as periodic oscillations about a reference point known as hunting when 16 an integral control is employed in the control scheme. Table 1 shows the effects and type of 17 friction as highlighted by Armstrong et. al.(1994). It is observed that, each of task is 18 dominated by at least one friction effect ranging from stiction, or/and kinetic to negative 19 friction (Stribeck). Hence, the need for accurate compensation of friction has become 20 important in high precision motion control. Several techniques to alleviate the effects of 21 friction have been reported in the literature (Dupont and Armstrong, 1993; Wahyudi, 2003; 22 Tjahjowidodo, 2004; Canudas, et. al., 1986). 23 One of the successful methods is the well-known model-based friction compensation 24 (Armstrong et al., 1994; Canudas de Wit et al., 1995 and Wen-Fang, 2007). In this method, 25 the effect of the friction is cancelled by applying additional control signal which generates a 26 torque/force. The generated torque/force has the same value (or approximately the same) 27 with the friction torque/force but in opposite direction

Piston driven yaw mechanism

Masteroppgave i mekatronikk MAS 500 Universitetet i Agder 2014The current thesis presents a piston driven yaw mechanism for wind turbines. Traditionally the yaw mechanismhas been one of the mayor contributors to down time and repair has been costly. The proposed designaims to improve the reliability of the yaw mechanism by reducing the point loads and by using hydrauliccylinders instead electrical motors to generate torque. In addition the design is modular allowing the mechanismto be disassembled and components to be replaced without the requirement of complicated or costlymachinery. The current thesis presents an analysis of the state of the art and discusses concepts which maysolve some of the challenges with existing yaw mechanisms. Further on a conceptual model of the mechanismis developed. Modelling and simulation is carried out to verify the suitability of the concept. It is found thatthe proposed yaw mechanism may be suitable for modern wind turbines and that the design may increasethe reliability and reduce cost of repair compared to current solutions