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ELECTRO – PROPORTIONAL VALVES

ELECTRO – PROPORTIONAL VALVES. 1. HYDRAULIC CONTROL TECHNOLOGY. Servo valve. New Series Proportional valves. Closed Loop Proportional. Hybrid series. Increasing Performance. Open Loop Proportional. Proportional Valves. Conventional Valves. 2. Conventional Mechanical

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ELECTRO – PROPORTIONAL VALVES

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  1. ELECTRO – PROPORTIONAL VALVES 1

  2. HYDRAULIC CONTROL TECHNOLOGY Servo valve New Series Proportional valves Closed Loop Proportional Hybrid series Increasing Performance Open Loop Proportional Proportional Valves Conventional Valves 2

  3. Conventional Mechanical Single In Steps Complex Large Complicated Not Available SL. No. 1 2 3 4 5 6 7 Description Setting Stage Control Slope Control Circuit Size of Blocks, Pipes Power Saving Circuit Feedback Proportional Electrical Multiple Smooth Slope Simple Small Simple Available COMPARISON BETWEEN CONVENTIONAL AND PROPORTIONAL VALVES 3

  4. DEVELOPMENT OF ELECTRO - PROPORTIONAL VALVES 1965 ~ 1970 1990 ~ Year 1975 ~ 1980 1980 ~ 1985 Combination of Pressure & FlowControl Valves Pressure Control & Flow Control Valves Power Matching Systems. Directional & Flow Control Valves EH- Series Pressure & Flow , Directional & Flow Control Valves. Power Matching Systems 4

  5. SALIENT FEATURES OF ELECTRO PROPORTIONAL VALVES Just Like Conventional Valve Basic Structure High Reliability Simple Easy to Use Easy to Maintain Longer Service Life Wet Armature Type Solenoid High Resistance Against Contamination Directly Operated Type Powerful Driving With Current Feedback Function, Dither Stable Control Amplifier

  6. DEVICES FOR THE PROPORTIONAL CONTROL Indication Feedback signal in Closed Loop Circuit Power Amplifier Setting Device Sensor Prop. Valve Manual Dialing Program Control Computer Control DC input type DC input with feedback type Slow up – down. Pilot Relief Valve Relief Valves Relieving & Reducing valves Flow control (& check) valves Throttle Valves Power Saving Valves Direction & Flow control Valves The Sensor detects the Controlled Pressure, Flow Rate and Speed etc., and converts it to electric signal. DC VOLTAGE DC CURRENT 6

  7. SIGNAL SEQUENCE Control Power Supply Hydraulic Power Supply Control Panel 0~10V Command Signal Prop. Valve Amplifier Actuator Sensor 7

  8. Coil Plunger Spring Force Magnetic Force D C Current ( Schematic Diagram of Solenoid ) PRINCIPLE OF OPERATION 8

  9. PRINCIPLE OF SOLENOID OPERATION ELECTRO MAGNET PERMANENT MAGNET 9

  10. PRINCIPLE OF BASIC SOLENOID OPERATION NO ELECTRIC CURRENT PLUNGER COIL Magnetic Field created which must travel through air. ELECTRIC CURRENT 1.) Attracts Plunger to an equilibrium position. 2.) Creates an output force. 3.) so that magnetic field can pass 100% through the iron. ELECTRIC CURRENT 10

  11. COMPARISON : FORCE V/S STROKE Conventional Proportional Force Force Stroke Stroke 100 % 100 % 70 % 70 % Force Force 30 % 50 % 30 % Stroke Stroke 11

  12. Spring Curve Spring Curve Force Force COMPARISON : FORCE V/S STROKE Proportional Conventional 100 % 70 % 50 % 100 % 70 % 30 % 30 % Stroke Stroke 12

  13. COMPARISON OF SOLENOID CONSTRUCTION Air Gap COIL CONVENTIONAL SOLENOID ARMATURE Air Gap COIL PROPORTIONAL SOLENOID ARMATURE 13

  14. CONSTRUCTION DETAILS OF PROP. SOLENOID Manual Adj. Screw Iron Core Bearing Air Vent Coil Spring Air Gap Plunger 14

  15. Maximum Flow Maximum Operating Valve Type Pressure Kgf/Cm2 1 2 3 5 10 20 30 50 100 200 300 500 1000 L / min Pilot Relief Valves 245 Relief Valves 245 03 06 10 Reducing & Relieving Valves 245 06 10 EH Series Flow Control (& Check)Valves 245 03 06 Flow Control & Relief Valves 245 03 06 10 Directional & Flow Cont.Valves 245 01 03 High Response Type 157 04 06 Directional & Flow Cont.Valves Pilot Relief Valves 245 Relief Valves 245 EBG 03 06 10 Reducing & Relieving Valves 245 06 10 206 W 02 03 06 10 Flow Control (& Check)Valves 245 W E Series 03 06 W W 03 06 10 Flow Control & Relief Valves 245 W W 03 06 10 03 06 Directional & Flow Cont.Valves 245 03 04 06 PROPORTIONAL HYDRAULIC CONTROL - RANGE 16

  16. 90 STROKE % 50 100 75 0 70 0 60 25 0 50 0 40 TIME ( ms ) STEP RESPONSE STEP SIGNAL 0 ~ 100 % Fig. Shows the Valve requires 80 ms to go from 0 to 100% Stroke and 70 ms to fully close. i.e., 150 ms is required to complete one cycle. 150 ms - 1 Cycle 1000ms ( 1 Sec ) - ? Cycles 1000 X 1 = 6.6 Cycles / Sec ( Or 6.6 Hz ) 150 100 STROKE % 50 0 80 0 70 TIME ( ms ) STEP SIGNAL 10 ~ 90 % STEP SIGNAL 25 ~ 100 % STROKE % TIME ( ms ) STEP RESPONSE : A RESPONSE MADE WHEN THE INPUT SIGNAL SUDDENLY CHANGES FROM A GIVEN VALUE TO ANOTHER GIVEN VALUE 17

  17. FREQUENCY RESPONSE • Frequency • Is the number of times any action occurs in a given measure of time. Unit is Hz (Cycles per Second) • Amplitude Response ( Gain ) • Is a ratio of output change to input change. Measured in dB (Decibels) 18

  18. Cyclic Out put Time Phase Lag in Degrees 90° Phase Lag 90° PHASE LAG • The time required for the output to recreate the input command. Measured in Degrees. Cyclic Input Phase Lag in Degrees Time 19

  19. 0.1 0.2 0.4 0.7 1 2 4 7 10 20 40 70 0 - 20 -10 - 40 -20 Gain ) - 60 -30 deg. - 80 ) -100 dB Phase Phase ( -120 Gain ( -140 -160 -180 Flow Rate : 2 L / min ± Pressure : 80 16 Kgf / Cm2 3 Trapped Oil Volume : 30 cm Viscocity : 30 cSt PROPORTIONAL ELECTRO – HYDRAULIC PILOT RELIEF VALVE • FREQUENCY RESPONSE Frequency ( Hz ) 20

  20. HYSTERESIS Hysterisis without Dither Hysteresis with Dither 200 180 160 140 120 100 80 60 40 20 200 180 160 140 120 100 80 60 40 20 Pressure Kgf / Cm2 Pressure Kgf / Cm2 0 200 400 600 800 0 200 400 600 800 Current ( mA ) Current ( mA ) Dead Band Dead Band 21

  21. PROPORTIONAL ELECTRO – HYDRAULIC PILOT RELIEF VALVE • With Safety Valve PLUNGER COIL SPRING POPPET PLUNGER SPRING SEAT AIR VENT Pr. Adj. Screw for Safety valve MANUAL PR. ADJ. SCREW IRON CORE TANK PORT PRESSURE PORT • Without Safety Valve 22

  22. Flow Rate : 2 L / min Kgf / Cm2 Trapped Oil Volume : 40 cm3 90 Viscocity : 30 cSt 70 Pressure 50 0.2 Sec 30 Step Signal 10 Time PROPORTIONAL ELECTRO – HYDRAULIC PILOT RELIEF VALVE • STEP RESPONSE 23

  23. Viscosity A 250 235 220 B 160 145 130 Pressure Kgf / Cm2 C 70 55 40 0 1 2 L / min PROPORTIONAL ELECTRO – HYDRAULIC PILOT RELIEF VALVE • FLOW RATE VS PRESSURE : 30 cSt Flow Rate 24

  24. 0.1 0.2 0.4 0.7 1 2 4 7 10 20 40 70 0 - 20 -10 - 40 -20 Gain ) - 60 -30 deg. - 80 ) -100 dB Phase Phase ( -120 Gain ( -140 -160 -180 Flow Rate : 2 L / min ± Pressure : 80 16 Kgf / Cm2 3 Trapped Oil Volume : 30 cm Viscocity : 30 cSt PROPORTIONAL ELECTRO – HYDRAULIC PILOT RELIEF VALVE • FREQUENCY RESPONSE Frequency ( Hz ) 25

  25. 250 A 200 150 Pressure Kgf / Cm2 100 B 50 C 0 0 200 400 600 800 1000 Input Current mA PROPORTIONAL ELECTRO – HYDRAULIC PILOT RELIEF VALVE • CONTROL PRESSURE VS INPUT CURRENT 26

  26. PROPORTIONAL ELECTRO – HYDRAULIC RELIEF VALVE PROPORTIONAL PILOT RELIEF VALVE WITH SAFETY VALVE AIR VENT MANUAL PR. ADJ. SCREW SLEEVE SEAT SPRING POPPET Graphic Symbol VENT PORT TANK PORT PR. PORT 27

  27. Kgf/Cm2 200 160 120 0.2s Pressure 80 Step Signal 40 Time 200 L / min ) Flow Rate : Loading Volume : 1 ltr. Viscocity : 30 cSt PROPORTIONAL ELECTRO – HYDRAULIC RELIEF VALVE • STEP RESPONSE 28

  28. COMPARISON OF CONVENTIONAL & PROPORTIONAL PRESSURE CIRCUIT Conventional Circuit Proportional Circuit Switch ON Sol. a – d to get 4 different pressures Only One Valve is required ., By changing the Input Current, the Pressure can be changed. 29

  29. O M PROPORTIONAL ELECTRO – HYDRAULIC FLOW CONTROL VALVE PR. COMPENSATOR PISTON • 40 Series ( Direct Type ) INLET PORT DRAIN PORT Graphic Symbol OUTLET PORT SPOOL ORIFICE SLEEVE 31

  30. L / min 125 L / min 140 L / min 120 150 125 L / min 100 125 60 L / min 80 100 60 60 L / min Flow Rate 75 40 0.2s 50 0.2s 20 Step Signal 25 0 Step Signal 0 Time Time STEP RESPONSE 40 Ohm 10 Ohm Flow Rate 34

  31. Frequency ( ) Hz 0.1 0.2 0.7 1 2 4 7 10 30 0 0 10 20 - - 20 40 - - Gain ) 60 - ) 80 deg. - dB Phase 100 - 120 - Gain ( Phase ( 140 - 160 - 180 - ± Input Current : 460 70 mA Pressure : 70 Kgf / Cm2 FREQUENCY RESPONSE 40 Ohm 35

  32. Forward Backward Forward Backward Intermediate Speed EFG-* - PUMP PUMP Low Speed High Speed COMPARISON OF CONVENTIONAL & PROPORTIONAL FLOW CIRCUITS Sol. 1 Sol. 2 Sol. 1 Sol. 2 Signal Sol. 3 Sol. 4 Conventional Proportional 37

  33. LOAD SENSING - COMPARISON OF HEAT GENERATION HEAT GENERATED = P x Q x 860 Kcal / Hr 612 = 40 x 40 x 860 612 = 2248 Kcal / Hr 38

  34. VENT LINE Set At 100 Bar Increase pressure P T REMOTE CONTROL RELIEF VALVE LOAD SENSING - COMPARISON OF HEAT GENERATION 39

  35. LOAD SENSING - COMPARISON OF HEAT GENERATION w Load Pr. + 5 Kgf/Cm2 (10 + 5 = 15 Kfg/Cm2 ) Load Pressure = 10 Kgf / Cm2 Flow Control Valve Set At 100 Bar P T 40

  36. LOAD SENSING - COMPARISON OF HEAT GENERATION HEAT GENERATED = P x Q x 860 Kcal / Hr 612 = 40 x 15 x 860 612 = 843 Kcal / Hr 41

  37. CONVENTIONAL POWER SAVING VALVE FLOW CONTROL VALVE RELIEF VALVE TANK PORT DRAIN PORT INLET PORT OUTLET PORT 42

  38. PROPORTIONAL ELECTRO – HYDRAULIC RELIEF & FLOW CONTROL VALVE • 40 - 10 Series FLOW CONTROL SOLENOID PROPORTIONAL PILOT RELIEF VALVE WITH SAFETY VALVE TANK PORT DRAIN PORT INLET PORT OUTLET PORT 43

  39. POWER SAVING CIRCUIT Conventional Circuit Proportional Circuit Energy Saving Energy Saving Energy Saving Q Q Q Q Power loss Power loss Power loss Power loss P P P P • Load Sensing Circuit • Flow Matching Circuit 45

  40. PROPORTIONAL ELECTRO – HYDRAULIC DIRECTIONAL AND FLOW CONTROL VALVE Max. Op. Pr. : 250 Kgf / Cm2 Max. Flow : 01  30 L/ min 03  60 L/ min 46

  41. L / min 120 A B A B 100 80 P T P T 60 Flow Rate 40 20 0 1000 800 600 400 200 0 200 400 600 800 1000 mA Input Current PROPORTIONAL ELECTRO – HYDRAULIC DIRECTIONAL AND FLOW CONTROL VALVE • INPUT CURRENT V/S FLOW 48

  42. PROPORTIONAL ELECTRO – HYDRAULIC DIRECTIONAL AND FLOW CONTROL VALVE • PRESSURE DIFFERENCE V/S FLOW L / min 140 A B 750 mA 120 P T 700 mA Flow Rate 80 40 Valve Pres. Diff. 600 mA Kgf / Cm2 245 210 140 70 Kgf / Cm2 70 140 210 245 600 mA Valve Pres. Diff. 40 80 Flow Rate A B 700 mA 120 L / min 750 mA P T 140 49

  43. LINEAR VARIABLE DIFFERENTIAL TRANSFORMER ( LVDT ) INPUT SECONDARY COIL PRIMARY COIL SECONDARY COIL MOVEMENT IRON CORE OUTPUT 51

  44. HYBRID SERIES PROPORTIONAL VALVES 24 V DC Power Supply Pressure display panel (option) Power Amplifier Command Signal Voltage Input Pressure Sensor Incorporated Voltage Output for Pr. monitor Alarm Signal Output Proportional Electro Hydraulic Relief Valve 52

  45. Air Vent Air Vent SOL Air Vent SOL SOL Air Vent SOL SOL Air Vent INSTALLATION REQUIREMENT GOOD EXAMPLE BAD EXAMPLE SOL Air Vent 54

  46. TYPICAL APPLICATIONS • ELEVATORS • ROLLING MILLS • PLANERS • INJECTION MOULDING MACHINES • PRESSES • SURFACE GRINDING MACHINES 55

  47. Proportional Direction and Flow Control Valve with LVDT 55

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