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Proportional

hydraulics
Collection of
Transparencies

095061 GB

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095061
PROP.H.FOLIEN
D:OT-TP701-GB
10/2002
Dr. Frank Ebel
Thomas Ocker, Brbel Bhland
09.10.2002, Petra Schwarz, Wolfgang Schreiner

Festo Didactic GmbH & Co., 73770 Denkendorf/Germany, 2002


Internet: www.festo.com/didactic
e-mail: did@festo.com
The copying, distribution and utilization of this document as well as the
communication of its contents to others without expressed authorization is
prohibited. Offenders will be held liable for the payment of damages. All rights
reserved, in particular the right to carry out patent, utility model or ornamental
design registration.

Foreword

This set of overhead transparencies has been designed for the basic level
technology package TP700. The set of overhead transparencies and the technology
package form part of the Learning System for Automation and Technology from
Festo Didactic GmbH & Co.
The 28 overhead transparencies which comprise this set have been designed in
accordance with dictactic and methodological principles. Each transparency is
accompanied by a short explanatory text, which gives the instructor a brief overview
of of the training content covered by the transparency.
Training contents

Fundamentals of proportional hydraulics


Function and use of proportional hydraulic components
Electronic components for the actuation of proportional valves
Comparison with electro-hydraulic control systems

The text sheet includes a full illustration of the transparency, partly supplemented
by additional explanations and designations, which can be added to the
transparency by the instructor in the course of training.
The advantages of this concept are:
The instructor can expand the transparencies step by step in the course of
training
Lessons become more interesting
The available explanatory texts reduce the amount of preparation required by the
instructor
New!
Electronic presentation

The enclosed CD-ROM contains the entire overhead transparencies and


accompanying text of this edition in an electronically presentable form in the files
Prophydraulics_transparencies.pdf and Prophydraulics_text.pdf. In addition to
the screen presentation, which can be made in any order, the contents can be
printed out and text and graphics can be used for your own training preparations,
insofar as the functionality of the required Adobe Acrobat Reader permits this.
This freely distributable software is available on the CD-ROM in the currently valid
English Windows version for installation in the directory Acrobat_Reader. Please
start the file *.exe and follow the subsequent dialogue.

Festo Didactic GmbH & Co. Proportional hydraulics

Contents

Proportional hydraulic system ________________________________Transparency 1


Mobile hydraulics __________________________________________Transparency 2
Proportional valve activation _________________________________Transparency 3
Honing machine ___________________________________________Transparency 4
Electro-hydraulics __________________________________________Transparency 5
Proportional hydraulics______________________________________Transparency 6
Electro-mechanical transducers _______________________________Transparency 7
D.C. switching solenoid______________________________________Transparency 8
Proportional solenoid with intermediate ring ____________________Transparency 9
Proportional solenoid, stroke-controlled_______________________Transparency 10
Proportional solenoid, force-controlled ________________________Transparency 11
Proportional solenoid, components___________________________Transparency 12
Electronic activation _______________________________________Transparency 13
Proportional amplifier ______________________________________Transparency 14
Ramp shaper _____________________________________________Transparency 15
Minimum current Maximum current _________________________Transparency 16
Output stage (V/I converter) ________________________________Transparency 17
Pulse duration modulation __________________________________Transparency 18
Hysteresis _______________________________________________Transparency 19
Flow characteristic curves___________________________________Transparency 20
Control edge patterns ______________________________________Transparency 21
Piston opening ratio _______________________________________Transparency 22
Piston overlap ____________________________________________Transparency 23
Pressure relief valve, piloted ________________________________Transparency 24
Pressure regulating valve, piloted ____________________________Transparency 25
Flow control valve _________________________________________Transparency 26
4/3-way valve ____________________________________________Transparency 27
4/3-way valve, piloted _____________________________________Transparency 28

Festo Didactic GmbH & Co. Proportional hydraulics

Proportional hydraulics

Title

Proportional hydraulic system

Guide

Signal
input

Festo Didactic

Classification into signal control section and power section.


Signal processing has been further enhanced by the provision of
setpoint value and current signal conversion.
The multiple function of proportional valves reduces the number of
hydraulic components to a minimum.
Proportional solenoids form the interface between the signal control
section and the power section.

Actuators

Signal
processing,
control

Setpoint
generator

Signal
amplification

B
Proportional
valves

PLC

Power supply

701-01-GB

Power section

Power supply
Power section

Proportional hydraulics

Festo Didactic

PLC

P
Energieversorgung

Steuerteil

Proportional hydraulic system


701-01-GB

Proportional hydraulics

Title

Mobile hydraulics

Guide

Festo Didactic

Origins of mobile hydraulics. Long hose connections between


control valves and hydraulic drive components.
Ratio of hand lever movement to piston deflection is approximately
proportional.
Control pattern: High-precision controllability at start of hand lever
displacement, large flow rate change during hand lever movements
at end deflection.
In this instance, flow is not released until end deflection due to the
positive piston overlap.

High-precision controllability

Piston B
deflection

Flow
rate [Q]

B
Hand lever movement

Piston overlap
A
T

701-02-GB

Proportional hydraulics

Festo Didactic

High-precision controllability
Piston B
deflection

Flow
rate [Q]

B
Hand lever movement
Piston overlap
A

Mobile hydraulics
701-02-GB

Proportional hydraulics

Title

Proportional valve activation

Guide

Festo Didactic

Setpoint values are converted into magnetic flux and amplified.


By means of the proportional solenoid, magnetic flux is converted
into piston deflection within the hydraulic valve.
Actuation of proportional directional, pressure and flow control valves.

Directional valves

Pressure valves

Proportional amplifier

Proportional solenoid

Flow control

701-03-GB

Proportional hydraulics

Festo Didactic

Proportional valve activation


701-03-GB

Proportional hydraulics

Title

Honing machine

Guide

Festo Didactic

Typical machine tool employing a proportional hydraulic control


system.
Continuous path control on machine tools: Controlling of path,
speed and acceleration.
Smooth transition of upward and downward stroke of honing
machine in accordance with time function.

Cyl. stroke
advanced 1

retracted 0

701-04-GB

Time

Proportional hydraulics

Festo Didactic

Cyl. stroke
advanced 1

retracted 0

Time

Honing machine
701-04-GB

Proportional hydraulics

Title

Electro-hydraulics

Guide

Festo Didactic

Example for conventional electro-hydraulics:


Control of velocity stages.
Use of parallel switching flow control valve for control of velocity
stages.
Digital switching characteristics: only preset flow rates can be
invoked (example: flow control valve).
Extensive hydraulic circuit requirement.

01

23

Cylinder stroke

3
2
Y4

Y3

1
0
Time [t]
Y1

701-05-GB

Y2

Y1

Y2

Y3

Y4

Proportional hydraulics

Festo Didactic
01

23

3
Cylinder stroke

2
Y4

Y3

1
0
Time [t]
Y1

Y2

Y1

Y2

Y3

Y4

Electro-hydraulics
701-05-GB

Proportional hydraulics

Title

Proportional hydraulics

Guide

Festo Didactic

Example for proportional hydraulics:


Control of velocity stages.
Hydraulic circuit requirement considerably reduced, electrical signal
control section extended.
Additional requirements for commissioning: Setting of setpoint
values and ramp functions.
Analogue valve cross section openings according to setpoint values
and thus different flow range, i.e. actuator speeds.
Flexibility thanks to electrical control, e. g: an additional velocity
stage requires only one additional setpoint value.

01 2

3 4

IY1
Current
Time [t]

IY2
Cylinder
stroke 4

IY1

IY2
Y1

Y2
2

1
0

Time [t]

Y1

701-06-GB

Y2

Proportional hydraulics

Festo Didactic
01 2

3 4

IY1
Current
Time [t]
IY2
Cylinder
stroke 4

IY1

IY2
Y1

Y2
2

1
0
M

Time [t]
Y1

Proportional hydraulics
701-06-GB

Y2

Proportional hydraulics

Festo Didactic

Title

Electro-mechanical transducers

Guide

Proportional solenoid: Further development of switching solenoid.


The magnetic flux causes a force which remains constant
throughout the stroke. The force acts only in one direction. The
extent of the magnetic force is proportional to the magnetic flux.
Due to its force, the servo drive of the proportional solenoid is
particularly suitable for the direct actuation of standard proportional
valves.
Plunger coil: Also an electro-dynamic principle, whereby a force acts
on a current carrying conductor in the magnetic field. Depending on
the direction of current the plunger coil is deflected up or down.
Torque motor: The effects of the permanent and electro magnets
are superimposed. The magnetic force causes a torque to the right
or the left.
The servo drive, plunger coil and torque motor have a high natural
frequency, which makes them suitable for the indirect actuation of
highly dynamic proportional and servo valves.

Power consumption

701-07-GB

[W]

Proportional soleonid

Plunger coil

Torque motor

5 - 40

0.2 - 5

0.02 - 4

20 - 1000

8 - 80

2 - 40

Working stroke

[Nmm]

Linear deviation

(%)

0.5 - 6

1-7

1-2

Critical frequency

[Hz]

10 - 150

100 - 200

100 - 300

Proportional hydraulics

Festo Didactic

F
Proportional solenoid
Power consumption

x
Plunger coil

[W]

Working stroke [Nmm]


Linear deviation

(%)

Critical frequency

[Hz]

Electro-mechanical transducers
701-07-GB

x
Torque motor

Proportional hydraulics

Title

D.C. switching solenoid

Guide

Festo Didactic

Magnetic field lines of a coil.


Existence of a homogenous magnetic field within a coil without
magnet core or armature.
Radial air gap and axial air gap form different resistances in the
magnetic field.
The magnetic force acts on the armature mainly via the radial air
gap, since in this case the gap between the core and armature
remains small.

Radial air gap

Homogenous magnetic field

Magnetic field lines

701-08-GB

Axial air gap

Proportional hydraulics

Festo Didactic

D.C. switching solenoid


701-08-GB

Proportional hydraulics

Festo Didactic

Title

Proportional solenoid with intermediate ring

Guide

Different magnetic forces act on the armature via the axial air gap.
Reducing the magnetic field lines via the radial air gap by means of
installing a non-magnetisable intermediate ring.
The new distribution of the magnetic field line leads to a virtually
constant magnetic force pattern within the working stroke range.
1 = Magnetic force characteristic in the axial air gap
2 = Magnetic force characteristic in the radial air gap
3 = Summation characteristic curve

Radial
air gap
Axial air gap
a

Magnetic
force [N]

3
2

1 = Magnetic force characteristic in the axial


0
air gap
2 = Magnetic force characteristic in the radial
air gap
3 = Summation characteristic curve

701-09-GB

Working stroke
b 1mm

Piston
position

Proportional hydraulics

Festo Didactic

Magnetic
force [N]
60

a
b
c

30

0
Piston
position

Proportional solenoid with intermediate ring


701-09-GB

10

Proportional hydraulics

Festo Didactic

Title

Proportional solenoid, stroke controlled

Guide

The solenoid force is proportional to the electrical input signal.


Poppet principle: The valve cone is pressed against the valve seat
via a spring; the valve opens as soon as the hydraulic force on the
valve cone exceeds the pilot force, whereby the entire spring/
plunger system is moved back.
Spool principle: the valve piston is pushed against the spring, the
stroke movement ceases when the magnetic force and the spring
force are in equilibrium.
Force/stroke characteristic curves:
Magnetic force with specified current values in relation to plunger
position; characteristic curve of a pressure loaded spring.

Poppet principle
Characteristic force/stroke curves
Magnetic
force [N]

Characteristic
spring
curve

Spool principle
3

0
Piston
Working stroke Idle stroke position

701-10-GB

Proportional hydraulics

Festo Didactic

Characteristic force/stroke curves


Magnetic
force [N]
60

30

0
Piston
position

Proportional solenoid, stroke controlled


701-10-GB

11

Proportional hydraulics

Festo Didactic

Title

Proportional solenoid, force controlled

Guide

The solenoid force is proportional to the electrical input signal.


Only poppet type valves can be operated via force controlled
solenoids.
This valve is used as a pilot pressure valve for directional or
pressure control valves because of the reduced flow rates.

Force/current characteristic curve

Magnetic
force
F [N]

T
Poppet principle (only)
F~I
P

Magnetic flux I [A]

701-11-GB

Proportional hydraulics

Festo Didactic

P
Magnetic
force
F [N]

Magnetic flux I [A]

Proportional solenoid, force controlled


701-11-GB

12

Proportional hydraulics

Festo Didactic

Title

Proportional solenoid, components

Guide

Construction of proportional solenoids.

D.C. solenoid group.

Representation of the most important components of a


proportional solenoid.
Electro-mechanical transducer: the electrical input signal is
converted into a mechanical output signal.

Electrical connection

Venting screw

Non-magnetisable
inner ring
Control cone

Compensating
spring

Core magnet

Plain bearing
Guide rod (stem)
Housing
Stop/Guide disc
Barrel magnet
Exciting coil

701-12-GB

Armature

Proportional hydraulics

Festo Didactic

Proportional solenoid, components


701-12-GB

Proportional hydraulics

13

Title

Electronic activation

Guide

Festo Didactic

Control stages of a proportional amplifier for magnetic flux


generation.
The input signal is set by means of ramp time, minimum or
maximum current and pulse duration modulation.
Both the amplification of the signal and the conversion by means
of a V/I converter take place during the output stage.
Proportional solenoid valves are to be actuated via an adjustable
D.C. current of 0 to 800 mA.

V
I

Y1

Y2

V
I

Setpoint
specification

701-13-GB

Ramp
setting

Setting
of
amplifier
characteristic

Pulse-duration
modulation

V/I-converter

Proportional
valve

Proportional hydraulics

Festo Didactic

V
I

V
I

Electronic activation
701-13-GB

Y1

Y2

14

Proportional hydraulics

Festo Didactic

Title

Proportional amplifier

Guide

Control panel of a setpoint and amplifier card.

W1 - W8: Input of up to 8 setpoint values.

R1 - R4: Setting of ramps. TIME = Ramp time.

IA - IB: Setting of initial, jump and maximum current.

24V, 0V: Supply voltage.

Liquid crystal display for representation of all parameters.

+24V

+24V

+24V

+24V

W1

I1

I2
R1

I3

OUT

W1 W2

R2
R3

W2

W3
W4

R4

IB
W1
W2

W5
TIME

INT W1

W6
W7

FUNCTION

INT W2

D/E OUT W8
CONTRAST

0V

701-14-GB

0V

0V

FUNCTION
IA
IA BASIC
IB BASIC
IA JUMP
IB JUMP

INT W1
IA MAX
INT W2
IB MAX
D/E
DITHERFREQ.
CONTRAST

OE A
OE B

0V

Proportional hydraulics

Festo Didactic

+24V

+24V

+24V

+24V

W1

I1

I2
R1
R2
R3

I3

OUT

W1 W2

W2

W3
W4

R4

W2

W5
TIME

INT W1

W6
W7

FUNCTION

INT W2

D/E OUT W8
CONTRAST

0V

0V

0V

Proportional amplifier
701-14-GB

FUNCTION
IA
IA BASIC
IB
IB BASIC
W1
IA JUMP
IB JUMP

INT W1
IA MAX
INT W2
IB MAX
D/E
DITHERFREQ.
CONTRAST

OE A
OE B

0V

Proportional hydraulics

15

Title

Ramp shaper

Guide

Left: Signal transmission in switching hydraulics.


Right: Signal transmission in proportional hydraulics with ramp shaper.
Use of ramps for adjustable acceleration or delay of hydraulic drive
components.
Angular setting: The ramp angle determines the adjustable speed of
the valve piston.
Elimination of pressure peaks and switching impacts in the hydraulic
system.
Displacement positions:
0: Retracted end position
1: Acceleration completed
2: Delay initiated (signal generator)
3: Forward end position

Displacement

Displacement
Signal generator

3
2

3
0

Festo Didactic

0 1

23

Cylinder

1
0

0
t0

t 3 Time [t]

t0

t1

t2 t3

Time [t]

Y1
100%
Control
signal

Y1

0%
t0

t1

t2 t3

Time [t]

Y1
1
Y1

1
Input
signal

Y2
0

0
t0

701-15-GB

Signal generator

Time [t]

t0

t2

Time [t]

Y2

Proportional hydraulics

Festo Didactic

Displacement

Displacement
3
2

3
0

0 1

23

1
0

0
t0

t 3 Time [t]

t0

t1

t2 t3

Time [t]

Y1
100%
Y1
0%
t0

t1

t2 t3

Time [t]

t2

Time [t]

Y1
1
Y1

Y2
0

0
t0

Time [t]

t0

Ramp shaper
701-15-GB

Y2

16

Proportional hydraulics

Festo Didactic

Title

Minimum current Maximum current

Guide

Setting of minimum and maximum current for adjustment of


proportional directional control valve to flow rate of hydraulic pump.
Minimum current for adjustment of jump current to control edge.
Maximum current or adjustment of maximum cross section of the
opening in relation to flow rate QPump.
A linear characteristic curve runs between minimum and maximum
current.

[mA]I
80
0

Imax Setting

Amplifier
characteristic

Setting I min

0 Setpoint value 10 Volt

Q 0

s = min.

701-16-GB

Q max.

s = max.

Proportional hydraulics

Festo Didactic

I [mA]
800

Setpoint value 10 Volt

Minimum current Maximum current


701-16-GB

17

Proportional hydraulics

Title

Output stage (V/I converter)

Guide

Festo Didactic

The setpoint voltage is converted into a magnetic flux in the output


stage.
Closed-loop control of magnetic flux through comparison of setpoint
value and actual value on the measuring shunt RM.
The closed control loop is created by means of connecting the
actual value via the feedback resistor RR.
The closed control loop eliminates the effects resulting from
operating voltage fluctuations and/or the effects resulting from
proportional solenoid heating.
The solenoid coil has an ohmic resistor RS and an inductive resistor
LS.

VI Input signal
R I Input resistance

VV Power supply voltage


RS Coil: Ohmic resistor
LS Coil: Inductive resistor
Solenoid coil

RR Feedback resistor

RS
LS

RM Measuring shunt

701-17-GB

Proportional hydraulics

VI

Festo Didactic

VV

RI

RS

RR

LS

RM

Output stage (V/I converter)


701-17-GB

Proportional hydraulics

18

Title

Pulse duration modulation

Guide

Solenoid
voltage

Festo Didactic

Recording of pulsed voltage signals and the associated magnetic


flux.
The output voltage is maintained at a constant level. The switch-on/
switch-off ratio (pulse duration) within a time period T influences the
size of the effective magnetic flux.
Clean-switching operations prevent excessive heating of the output
stage and power dissipation is kept to a minimum.
An oscillating output current is obtained thanks to pulse duration
modulation. Sliding friction prevails at the plunger thanks to this
dither effect and the hysteresis is improved.

V
24 V

T = Duty cycle

I eff = Effective
magnetising current
0
Time
V
24 V

I eff
0
Time
V
24 V

T
I eff

0
Time

701-18-GB

Proportional hydraulics

Festo Didactic

T = Periodendauer

24 V I eff
0Time
V

24 V I eff
0Time
V

24 V I eff

0Time

Pulse duration modulation


701-18-GB

19

Proportional hydraulics

Title

Hysteresis

Guide

Festo Didactic

The friction of the valve piston spool causes a resistance to


directional movement.
Hysteresis: Differential current during approach of a pressure or
flow rate value from different directions.
Pulse duration modulation: Reduction of hysteresis by means of
continuous slight oscillating movement of the piston spool (sliding
friction).
Avoidance of pressure peaks in the hydraulic system.

p [bar]

50
40
30
20
Pulse duration
modulation

10

701-19-GB

100 200 300 400 500 600 700 800

I [mA]

Proportional hydraulics

Festo Didactic

p [bar]
50
40
30
20
Pulse duration
modulation

10

100 200 300 400 500 600 700 800 I [mA]

Hysteresis
701-19-GB

20

Proportional hydraulics

Title

Flow characteristic curves

Guide

Festo Didactic

Representation of control piston with different control notches;


Representation of the corresponding flow characteristic curves.
Delta control edge pattern: Precision controllability for small volumetric flow rates, clear changes within the range of large volumetric
flow rates.
The stroke travel of a piston with control notches corresponds to the
maximum length of the notch opening.

Q
[l/min] 8
6
4
2
0
100

400

700 I [mA]

100

400

700 I [mA]

Q
[l/min] 8
6
4
2
0

701-20-GB

Proportional hydraulics

Festo Didactic

Q
[l/min] 8
6
4
2
0
100

400

700 I [mA]

100

400

700 I [mA]

Q
[l/min] 8
6
4
2
0

Flow characteristic curves


701-20-GB

21

Proportional hydraulics

Title

Control edge patterns

Guide

701-21-GB

Festo Didactic

Control edge pattern for the purpose of determining the flow


behaviour of the valve.
The adjustment of flow behaviour is linear, progressive, degressive
or generally according to the task.
Number of precision control openings on the periphery of the control
piston depending on valve function.
The sleeve system is easier to produce in terms of production
technology.

Proportional hydraulics

Festo Didactic

Control edge patterns


701-21-GB

22

Proportional hydraulics

Title

Piston opening ratio

Guide

Festo Didactic

Example: Actuation of a 2:1 cylinder.


The ratio of the valve flow cross sections is adjusted to the cylinder
inlet and outlet by means of control edge pattern.

Cylinder 2:1

701-22-GB

Proportional hydraulics

Festo Didactic

Piston opening ratio


701-22-GB

23

Proportional hydraulics

Festo Didactic

Title

Piston overlap

Guide

Representation of positive, negative and zero overlap.

Alternative designations: Overlap, underlap and zero intersection.

The opening of the valve port is dependent on the notched opening


in relation to the control edge.
The flow rate is also adjusted by means of the throttle opening ratio
of the control piston. The number of radially configured notches on
the control piston.

QL

QA
positive

X
>0

QB
QA

zero

QL

X
=0

QB

X
QL

QA
negative

X
<0

701-23-GB

QB

Proportional hydraulics

Festo Didactic

QL

QA

QB
QA

QL

X
QB

X
QL

QA

X
QB

Piston overlap
701-23-GB

24

Proportional hydraulics

Title

Pressure relief valve, piloted

Guide

Festo Didactic

Sectional view of a pressure relief valve.


The mode of operation corresponds to that of a conventional,
piloted pressure relief valve.
Piloted stage: the force set for the proportional solenoid is transferred to the pilot poppet via the spring.
As soon as the pressure acting on the pilot valve exceeds the value
set, the poppet valve opens. The venting control flow generates a
pressure drop at the main stage, whereby this opens.

p [bar]
5
4
3
T

1
TY

P
0

701-24-GB

20

40 I [mA]

Proportional hydraulics

Festo Didactic

p [bar]
50
40
30
T

20

10
TY
P
0

200

400 I [mA]

Pressure relief valve, piloted


701-24-GB

25

Proportional hydraulics

Festo Didactic

Title

Pressure regulating valve, piloted

Guide

Sectional view of a piloted pressure regulating valve.

Reduction of system pressure to a specific value.

Application for subranges within a hydraulic system.

P
A

701-25-GB

PY

Proportional hydraulics

Festo Didactic

A
PY

Pressure regulating valve, piloted


701-25-GB

26

Proportional hydraulics

Festo Didactic

Title

Flow control valve

Guide

Sectional view of a flow control valve.

Normal position: all ports are closed.

Depending on the piston deflection, control cross sections (holes in


the piston, control sleeve) and thus the flow are changed.

AB

PT

Q
l
[
]
min
8

Flow characteristic curve

6
4
2
P

701-26-GB

100 200 300 400 500 600 I [mA]

Proportional hydraulics

Festo Didactic

AB

PT
Q
[

l
]
min
8
6
4
2
0

Flow control valve


701-26-GB

100 200 300 400 500 600 I [mA]

27

Proportional hydraulics

Title

4/3-way valve

Guide

Festo Didactic

Essential functional components: Proportional solenoids, main spool,


reset spring.
Multiple functions: Directional control, speed control, hydraulic
clamping of power components (throttle opening ratio).

AB

PT

T B P A

701-27-GB

Proportional hydraulics

Festo Didactic

AB

PT

4/3-way valve
701-27-GB

28

Proportional hydraulics

Title

4/3-way valve, piloted

Guide

Festo Didactic

Pressure relief valves for pilot control of a 4/3 proportional


directional control valve.
Electrical signal to one of the two proportional solenoids increases
the pressure inside the control chamber of the main spool to a
specified value (relief pressure).
The control piston is moved up to the equilibrium position with the
opposing spring action.
High control force due to minimum control pressure of 25 bar
eliminates sensitivity to disturbance factors. This is however
associated with continuous control oil consumption.
Without an electrical signal, the control piston is centred by means
of the springs.

AB

PT

Actuation B

Actuation A

701-28-GB

Proportional hydraulics

Festo Didactic

AB

PT

4/3-way valve, piloted


701-28-GB

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