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Modelling and simulation of a hydraulic loadsensing system in the cocovila

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Article · January 2008

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6th International DAAAM Baltic Conference
INDUSTRIAL ENGINEERING
24-26 April 2008, Tallinn, Estonia

MODELLING AND SIMULATION OF A HYDRAULIC LOAD-

SENSING SYSTEM IN THE COCOVILA ENVIRONMENT

Grossschmidt, G. and Harf, M.

Abstract: In this paper we discuss the parameters. The results of the simulations
design of a hydraulic-mechanical load- are as initial data for further simulations of
sensing system using modelling and dynamics.
simulation in an intelligent programming
environment. The approach is based on 2. MULTI-POLE MODELS
using multi-pole models and signal-flow
graphs of functional elements, enabling Generally, multi-pole models [2, 3] repre-
methodical, graphical representation of sent oriented mathematical relations bet-
mathematical models of large and ween pairs of input and output potential
sophisticated fluid power systems. and flow variables of functional elements.
Modelling and simulation of separate The multi-pole models take into account
objects, subsystems and the whole system the signal propagation in both directions as
are discussed. it occurs in hydraulic and mechanical
Keywords: Fluid power system, multi-pole systems. When composing a model of the
modelling, intelligent programming fluid power system, multi-pole models of
environment, simulation. necessary components must be connected
through poles. Composing of multi-pole
1. INTRODUCTION models enables one to find the best model,
where all the oriented causalities of objects
Fluid power systems, in which working are graphically settled.
pressure (pressure in pump output) is kept The mathematical dependences between
proportional to load, are called hydraulic variables of functional elements (e.g.
load-sensing systems. Such systems are various hydraulic flow control and pressure
mainly used in mechanisms containing control valves) are convenient to express as
numerous drives to run with the purpose to oriented graphs.
save energy.
Hydraulic load-sensing systems are 3. HYDRAULIC-MECHANICAL
automatically regulating systems with LOAD-SENSING SYSTEM
number of components and feedbacks. A
very precise parameter setting is required In Fig. 1, the variable displacement axial
to make the system function. piston pump is driven by an electric motor
An intelligent programming environment M. Hydraulic-mechanical control of the
CoCoViLa [1] providing automatic pro- pump volumetric flow is performed by
gram synthesis and visual programming control valve and positioning cylinder. The
features is used as a tool in modelling and feeding chain of the hydraulic motor RVerbr
simulation. contains tube RL-zu, measuring valve RVW
with pressure compensator RIDW and check
In the paper we consider modelling and
valve, meter-in throttle edge RSK-zu and
simulation of steady state conditions. This
connection elements.
enables to set up system configuration and
 RIDVW
p0 = const

Fig. 1. Scheme of the hydraulic–mechanical load-sensing system

The output chain of the hydraulic motor automatic. The compiled program then
RVerb contains a meter-out throttle edge provides a solution for the problem
RSK-r, and tube RL-ab. The device contains specified in the scheme, and the results it
load-sensing pressure feedback. Feedback provides can be fed back into the scheme,
pressures have been taken directly from the thus providing interactive properties.
measuring valve with pressure compen- Automatic synthesis of programs is a
sator RIDVW. technique for the automatic construction of
programs from the knowledge available in
4. COCOVILA PROGRAMMING specifications. Having a specification of a
ENVIRONMENT class, we are, in general, interested in
solving following problems:
CoCoViLa is an intelligent programming
• find an algorithm for computing the
environment, which supports declarative
values of components y1, ..., yn from the
programming in a high-level language,
given values of components x1, ..., xm;
automatic program synthesis and visual
• find an algorithm for computing the
programming. CoCoViLa is implemented
values of all components that can be
in the Institute of Cybernetics at the Tallinn
computed.
University of Technology, since 2005. The
CoCoViLa environment is Java based, free The automatic synthesis of programs is
and platform-independent. based on proof search in intuitionistic
propositional logic.
CoCoViLa supports a language designer in
the definition of visual languages, From a user’s point of view the CoCoViLa
including the specification of graphical framework consists of two components:
objects, syntax and semantics of the Class Editor and Scheme Editor. The Class
language. CoCoViLa provides the user Editor is used for defining models of
with a visual programming environment, components of schemes as well as their
which is automatically generated from the visual and interactive aspects. The Scheme
visual language definition. Editor is a tool for the language user. It is
When a visual scheme is composed by the intended for developing schemes and for
user, the following steps – parsing, compiling (synthesizing) programs from
planning and code generation – are fully the schemes according to the specified
semantics of a particular domain. The The scheme editor is fully syntax directed
environment generated for a particular in the sense that the correctness of the
visual language allows the user to draw, scheme is forced during editing: drawing
edit and compile visual sentences syntactically incorrect diagrams is
(schemes) through language-specific impossible.
menus and toolbars. When the visual classes have been built by
Having developed the visual language we software developers who must understand
are able to load it in the Scheme Editor and the problem domain as well, the language
build schemes by putting visual objects on user need not be a software expert, but can
the drawing canvas and connecting them work on the level of visual programming,
through ports. arranging and connecting objects to create
a scheme.

Fig. 2. Multi-pole model of the hydraulic-mechanical load-sensing system

Load-sensing system components: VP - Displacement of the control valve; resH, resG –
Hydraulic resistors; RVP - Meter-in throttle edge of the control valve; IEH1-3, IEH2-2m -
Hydraulic interface elements; ZV - Positioning cylinder; REL – Constant resistor; RVT -
Meter-out throttle edge of the control valve; PV - Variable displacement pump; ME -
Electric motor; tubeH, tubeG - Tubes; RIDVWlin - Measuring valve with pressure
compensator; RSKZ - Meter-in throttle edge for hydraulic motor; MH - Hydraulic motor;
RSKA - Meter-out throttle edge for hydraulic motor.
Simulation task components: dynamic Process – Process organizer; constant Source,
dynamic Source – Sources; Graph drawings.
5. COMPOSING MODEL OF THE First, hydraulic motor and hydraulic pump
FLUID POWER SYSTEM parameters must be chosen.
Second, the fluid and its properties must be
Simulation of steady state conditions in the chosen. Cinematic viscosity and density
NUT environment has been considered in depending on the pressure are calculated at
[4]. Here, the advanced simulation of each step.
steady state conditions in the CoCoViLa Third, initial approximate values of
environment is considered. pressures and pressure drops for pump
The multi-pole model (Fig. 2) represents control must be set up. In our case
the scheme of the load-sensing system maximum working pressure pmax=250 bars,
(Fig. 1). pressure drop in measuring valve ΔpIDW =
To build up the multi-pole model it is 5…7 bars, pressure drop in measuring
necessary to decompose the scheme of the valve with pressure compensator ΔpIDVW =
load-sensing system into logical compo- 14…19 bars, pump control system feeding
nents and subsystems. pressure p0 = 60 bars and pump control
Models of the following components of the pressure pCP = 7…20 bars have been taken.
load-sensing system have been developed: Fourth, maximum displacements of the
electric motor, variable displacement axial valves must be set up.
piston pump, hydraulic-mechanical cont- Fifth, all the models of components must
roller, valve block, hydraulic motor, tubes be tested separately. For each component
and multiple tube connection elements. the simulation problem must be composed
Model of the hydraulic-mechanical cont- and input signals must be chosen.
roller includes models of control valve, Behaviour of the component must be
meter-in throttle edge, meter-out throttle simulated. Initial approximate components
edge, constant resistor and positioning parameters values (stiffness of springs,
cylinder with swash plate. geometry of working slots of valves, etc.)
Model of the valve block includes a must be refined as a result of simulations.
measuring valve with pressure compen- Sixth, the separately tested components
sator and check valve, meter-in and meter- models must be connected into more
out throttle edges of the hydraulic motor. complicated subsystems, tested in
The multi-pole model of the whole load- behaviour and refined if necessary.
sensing system has been built up using the Seventh, model of the whole load-sensing
components models. First, necessary system must be built up and simulation
components have been connected through tasks must be solved.
poles. Second, variables of connection If possible, steps 5…7 should be supported
poles have been defined as inputs or by testing on pilot models and using the
outputs for each component depending on results for refining the parameters and
required causalities [2]. models for further simulations.

6. SIMULATION AND DESIGN 7. SIMULATION OF A SUBSYSTEM

STEPS
The hydraulic-mechanical controller
The most important stage in design of a includes constant pressure feeding that
hydraulic load-sensing system is enables to make feedback independent of
parameters specification. In order to help hydraulic pump pressure. The simulation
designer to find better solutions, computer task description of steady state conditions
simulation technology is proposed that of the hydraulic-mechanical controller is
includes following steps. shown in Fig. 3.
 8. SIMULATION OF THE
LOAD-SENSING SYSTEM

The simulation task for steady state

conditions of the load-sensing system is
shown in Fig. 2.
Dependences on the displacement of the
directional valve from 0.0024 to 0.0068 m
(the load moment of the hydraulic motor is
constant 65 Nm) are calculated (Fig. 5, 6).
In Fig. 5, displacement of the control valve
(3) drops from 0.003 to 0.00025 m, pump
control pressure (1) drops from 19 to 5 bars
Fig. 3. Simulation task description of the and pump volumetric flow (2) increases
hydraulic-mechanical controller from 0 to 0.0015 m3/s.
Notations: VP - Displacement of the
control valve; RVP - Meter-in throttle edge
of the control valve; ZV - Positioning
cylinder; REL – Constant resistor; RVT -
Meter-out throttle edge of the control
valve; IEH1-3 - Hydraulic interface
element; p1p2 – Pressure difference
calculator; static Process – Process
organizer; constant Source, static Source – Fig. 5. Simulated graphs of the system
Sources; Graph drawing.
In the ideal case all the dependences should
Simulation results are shown in Fig. 4. The be linear. As the shape of the graphs
hydraulic-mechanical controller has been depends mostly on the passage areas of the
simulated in the case the pressure throttle edges of the valves it is very
difference applied to the control valve difficult to achieve the exact linearity.
changes from 14.1 to 19.1 bars.

Fig. 4. Simulated graphs of the hydraulic- Fig. 6. Simulated graphs of the system
mechanical controller In Fig. 6, angular velocity of the hydraulic
Then the control valve moves from 0 to motor (3) increases from 0 to 224 rad/s.
0.00275 m (2). Pressure interval for pump Output power of the electric motor (4) in
volumetric flow regulation from max to the case of zero volumetric flow (see (2) of
min (3) is 4…18 bars. Volumetric flow to Fig. 5) of the pump is ~600 W. For pump
the control valve (1) increases from control we need ~300 W electric motor
0.000025 to 0.0000425 m3/s. Position power. Increasing the volumetric flow
angle of the pump swash plate (4) drops cause the output power of the electric
from maximum 0.3264 to 0 rads. motor to grow until 22400 W.
 The efficiency coefficient of the hydraulic and moving to more complicated
pump (2) rapidly rises to 0.90. The systems.
efficiency coefficient of the whole load- • Iteration methods are used in cases of
sensing system (1) rises rapidly to 0.55 and loop dependencies that may appear
then rises slightly to 0.70. between component models when they
are connected together into more
9. SIZE AND COMPLEXITY complicated ones.
As a result of the current research, a
The package for modelling and simulation
simulation system is proposed that enables
of steady state conditions of the load-
one to perform fast computer experiments
sensing system contains:
at the first stage of design.
• 34 classes, including 24 load-sensing
The approach is original and there is
system component classes;
difficult to find similar works.
• more than 1000 variables;
• 11 variables that have to be iterated
Acknowledgement: This research was in
during the computations;
part supported by the Estonian Science
• 52 links between system components.
Foundation (Grant No. 7091).
Java code of the automatically constructed
algorithm for solving the simulation task of
the load-sensing system contains 2892 11. REFERENCES
lines and includes 4 algorithms for solving
subtasks. Simulation time is 2.84 s. 1. Grigorenko, P., Saabas, A. and Tyugu,
E. COCOVILA – Compiler-Compiler for
10. CONCLUSIONS Visual Languages. Proc. of the 5th
Workshop on Language Descriptions,
The main features of the approach pro- Tools and Applications, Edinburgh, 2005,
posed in the paper are as follows. v. 141, n. 4 of Electron. Notes in Theor.
• Mathematical models of the functional Comput. Sci., pp. 137-142. Elsevier.
elements are composed as multi-pole 2. Grossschmidt, G. and Vanaveski, J.
models taking into account signal “Causality of Mathematical Models of
propagation in both directions. Technical Systems”. Proc. of the 12th
• Used multi-pole models can have European Simulation Multiconference
various causalities. ESM´98, June 16-19, 1998, Manchester,
• The mathematical model of the fluid United Kingdom, pp. 191-195.
power system contains models of 3. Grossschmidt, G., Vanaveski, J. and
components and carries the full Harf, M. “Simulation of Hydraulic Chains
information about connections of using Multi-pole Models in the NUT
input/output variables, which express Programming Environment”. Proc. of the
the considered mathematical causalities 14th European Simulation Multiconference
and guarantees the completeness of the ESM’2000, May 23-26, 2000, Ghent,
model. Belgium, pp. 709-713.
• Using the CoCoViLa programming 4. Grossschmidt, G. and Harf, M. Design
environment enables one in flexible way of a Hydraulic-Mechanical Load-Sensing
compose and experiment with various System using Object-Oriented Modelling
large and complicated models. and Simulation. In: 21st European
Automatic program synthesis allows Conference on Modelling and Simulation
fast describing and solving a great ECMS 2007, June 4-6, 2007, Prague,
number of simulation tasks. Czech Republic, pp. 383 – 390.
• Simulation is performed step by step,
starting from simulation of components

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