Var Pump

How to Understand
Variable Pump
Controls
Brendan Casey
Marian Tumarkin
How to Understand Variable Pump Controls 2
Copyright © 2007 Brendan Casey & Marian Tumarkin
All rights reserved. No part of this electronic book may be reproduced or

transmitted in any form or by any means, electronic, mechanical, photocopying,
and recording or otherwise, without the prior, written permission of the
publisher.
The contents of this book reflect the author’s views acquired through his
experience in the field under discussion. The information in this document is
distributed on an “As is” basis, without warranty. Every effort was made to
render this book free from error and omission. However, the author, publisher,
editor, their employees or agents disclaim liability for any injury, loss, or damage
to any person or body or organization acting or refraining from action as a result
of material in this book, whether or not such injury loss or damage is in any way
due to any negligent act or omission, breach of duty, or default on the part of
the author, publisher, editor or their employees or agents.
First published in 2006 by

HydraulicSupermarket.com
PO Box 1029
West Perth WA 6872
Australia
Email: info@HydraulicSupermarket.com
Web: http://www.hydraulicsupermarket.com/books
About the Authors
Brendan Casey is the founder of HydraulicSupermarket.com and the best-

selling author of 'Insider Secrets to Hydraulics' the most comprehensive guide
to reducing hydraulic equipment operating costs ever published. A fluid power
expert with an MBA, he has more than 18 years experience in the design,
maintenance and repair of mobile and industrial hydraulic equipment.
Dr Marian Tumarkin has over 35 years of experience in the field of Fluid Power
with a Ph.D. from the National Academy of Science in Moscow. He is an
accomplished scholar in the field with over 50 published papers and 10 patents
to his name.
A highly experienced Fluid Power engineer, Marian has designed electro-

hydraulic systems for Russian and Australian Air Forces, Australian and
American automotive industries, as well as developing special purpose
machines. In this role, he was responsible for concept design and problem
solving, calculations and component selection, system testing and
troubleshooting.
Marian has extensive teaching experience both in Europe and Australia,

delivering basic and advanced Fluid Power subjects to undergraduate and post-
graduate students as well as engineers and technicians.
Copyright © 2007 ─ www.HydraulicSupermarket.com

PUMP DELIVERY CONTROL
DEFINITIONS
Pump delivery control is the most effective way to minimize wasted energy and
reduce power consumption in hydraulic systems. Two main methods of control
can be used:
• Delivery control of the fixed-displacement pump by changing the speed

of the pump shaft
• Delivery control of the variable-displacement pump by changing pump
displacement.
The first method is in an early stage of development and currently does not
have wide industrial applications. In the future it could become a popular
method of pump delivery control.
The second method is widely used. Adjustment of pump displacement is

accomplished in vane and radial piston pumps by varying the eccentricity, and
in an axial piston pump, by adjusting the angle of the swash plate.
For example, in a variable-displacement vane pump, control pressure moves

the stroke ring, which changes the
Displacement Stroke
ring’s eccentricity, and therefore, control ring
pump delivery – Fig. 5.1.
The types of control methods are

similar for different pumps and for
different manufacturers. Therefore,
to simplify explanation, different
types of displacement control are
considered below with regard to a
swash-plate axial piston pump. Fig. 5.1. Variable displacement vane pump
Pump delivery
Main components of a variable- 5 4 3

displacement, swash-plate axial
piston pump are shown in Fig. 5.2.
2
• 1 – Pump
• 2 – Swash plate
• 3 – Control piston
• 4 – Pressure here reduces pump 1
displacement
• 5 – Pressure here increases pump
displacement Fig. 5.2. Swash plate variable
displacement pump

A variable pump regulator is essentially a Control Piston

system of modular valves installed on the
pump – Fig. 5.3.
The regulator circuit diagram uses common

symbols for modular valves. The pump
module includes pump and control piston –
Fig. 5.4.
Fig. 5.3. Rexroth pump A4VSO
Fig. 5.4. Pump module with

single control piston
Two control pistons can be used to simplify

control – Fig. 5.5.
Fig. 5.5. Pump module with
two control pistons
The pump module is an actuator (Fig. 5.6) for a closed-loop proportional

control system.
Swash
Control input Control output
Plate
(Pressure Pc) (Pump Delivery Qp)
Angle
CONTROL
PUMP
PISTON
Fig. 5.6. Block diagram of the pump module
From a functional point of view, there are three common types of control. Each
of these presents a variety of options. The control system function is usually
described by a characteristic curve, which is the pump pressure-delivery
graph.

Q
1. PRESSURE CONTROL. The regulator
automatically adjusts pump delivery to
limit output pressure according to the
setting. Any pressure p1, p2, etc inside of
the limit (pset ≤ p) can be set using
manual or remote hydraulic adjustment – p2 p1 p
Fig. 5.7. Fig. 5.7. Pressure control
graph
Q
Q1
2. FLOW CONTROL. The regulator provides
Q2 constant pump delivery according to the
setting. Any flow rate Q1, Q2, etc below
maximum pump delivery Q can be set by
p manual adjustment of a variable throttle –
Fig 5.8.
Fig.5.8. Flow control graph
1
3. POWER CONTROL. The regulator Q1
constantly multiplies pressure and flowrate
and compares the result with the preset Q2 2
value of power Pset. If the pump output 3
Q3
power exceeds the set value, the regulator
reduces pump delivery. It means that for any
p1 p2 p3
particular pump delivery Q2 (see Fig. 5.9)
pressure p2 can be only Fig. 5.9. Power control graph
Psetting
p2 ≤
Q2
Hydraulic Setting
System
Structure of pump delivery regulator
is shown in Fig. 5.10.
Measurement Control
The functions of the regulator are:
ps
• Measure the system parameter pc
(pressure, flow rate, or Qp
hydraulic power)
• Compare it with the setting More
value displacement
• Give the command (control
pressure pc) to the control
piston Fig. 5.10. Structure of the regulator

Currently, the majority of regulators use proportional spools for their operation.
So, a proportional spool creates the control pressure pc, which changes the
angle of the swash plate and therefore, delivery of the pump.
Block diagram of the regulator (Fig. 5.11) describes its components from the
point of view of closed-loop control:
• Controller compares system parameter (pressure, or flow rate, or
hydraulic power) with setting and generates control signal (pressure pc)
proportional to the error (difference)
• Actuator (pump module) generates control output (pump delivery Qp) to
the object (Hydraulic System)
• Feedback measures controlled variable (pressure, flow rate, or hydraulic
power) and provides signal to controller
CONTROLLER
Setting Force Pc Qp
PROPORTIONAL OBJECT
ACTUATOR
+ SPOOL (SYSTEM)
Controlled Variable
FEEDBACK
Fig. 5.11. Block diagram of the pump delivery regulator
Important features of the regulator are:
• Controlled variable is measured directly (system pressure) or with a

dedicated feedback device (flow rate, or hydraulic power)
• The control output of the regulator is pump delivery - for any controlled
variable
• Two or more variables can be controlled by the regulator, but not

simultaneously because of the same control output
• Setting options can be manually, directly on the pump, or remotely from

the control panel

PRESSURE AND FLOW CONTROL

PRESSURE CONTROL (PRESSURE COMPENSATOR)
Function of the pressure regulator is to control system pressure ps according

to the setting p – Fig. 5.12. With ps below
setting p1, pump delivery Qp is maximum Qp 1
2
from point 1 to point 2. Decrease in
maximum flow rate with increasing
pressure is the result of increasing 3
internal leakage in the pump.
Regulator controls pump delivery and 4
therefore system pressure ps from point 2 p1 ps

through point 3 to point 4. Variation in the
controlled pressure (non-vertical lines) is Fig. 5.12. Pressure control graph
the result of regulator error
Principle of regulator operation is shown in
4 3 5
Fig. 5.13. The system pressure ps acts
System pressure ps
through connection (4) on the proportional

2 spool (3) against spring (5). Position of the
pc spool is proportional to system pressure.
1
Control pressure pc is proportional to spool
displacement. Therefore, position of the
control piston (1) is proportional to system
pressure. Setting of the spring (5)
determines the starting point of spool
movement. Below this setting the spool (3)
stays in the left position, connecting the right
chamber of the control piston (1) with the
tank, pc = 0, and pump displacement is
Fig. 5.13. Pressure control maximum.
The pressure regulator is a closed- Qp

Setting Pc
loop proportional control system CONTROLLER ACTUATOR HYDRAULIC
SYSTEM
with system pressure feedback
through the pipeline 4 – Fig. 5.14.
Ps Controlled Variable
Ps
FEEDBACK
Pressure (line 4)
Q module
ps
Fig. 5.14. Block diagram of the
Pump pressure regulator
module
Hydraulic circuit diagram for variable

displacement pump with pressure
Fig. 5.15. Pressure control circuit control is shown in Fig. 5.15

REMOTE PRESSURE CONTROL
Remote pump delivery control is required in two situations:

• Frequent adjustment of the setting parameters is desired
• Manual adjustment during system operation is required.
Remote pressure control arrangement is 7

shown in Fig. 5.16. System pressure ps is 5
determined by the setting of the pilot relief x
valve (7), located in a convenient position,
3
remote from the pump. When pressure ps Q
is below the setting of valve (7),
proportional control valve (3) gives the
command for maximum pump
ps
displacement. When pressure ps reaches
the setting of relief valve (7), it opens,
allowing the proportional spool to move to
the right, which reduces pump
displacement and, therefore, flow rate Q.
Remote
setting (7)
Fig. 5.16. Remote pressure control
Setting Pc Qp
CONTROLLER ACTUATOR HYDRAULIC
SYSTEM
Remote pressure control acts in
parallel with main setting – see
block diagram in Fig. 5.17
Ps Controlled Variable
Ps
FEEDBACK
(line 4)
7
Fig. 5.17. Block diagram of pressure

regulator with remote control 9
x 5
3
Q
Remote pressure control can be used in a two- ps
pressure (high-low) circuit by adding an ON -
OFF solenoid DCV (9) between the pump
module and the remote relief valve (7) –
Fig. 5.18. When the valve (9) is de-energized,
pressure ps is determined by the setting of the
spring (5). When the valve (9) is energized,
pressure ps is reduced to the setting of the
remote relief valve (7). Fig. 5.18. Remote two-pressure
control

FLOW CONTROL (LOAD SENSING)

Qp
Function of the flow regulator is shown in 1 2 3
Fig. 5.19. Pump delivery is controlled Q1
according to setting Q1 from point 1 through
point 2 to point 3. Small decrease of the set 4
flow rate (non-horizontal lines) is the result of
regulator error. From point 3 to 5 the system 5
relief valve limits maximum pressure. The ps
controlled flow does not depend on the pump
drive speed. Fig. 5.19. Flow control graph
ps 6 7 5
Principle of regulator operation is shown in
4 Fig. 5.20. The pressure drop ∆p = p − pS
across an adjustable throttle (6) in the pump
output line acts on the proportional spool, to
Qp pc alter control pressure pc and adjust the pump
displacement to maintain:
p
∆p = const and therefore Q P = const
The flow regulator is a closed-loop

proportional control system with flow
feedback via the throttle (6) and two
pipelines (4) and (7) – Fig. 5.21.
Fig. 5.20. Flow control
Setting Pc Qp
Any interference, for example CONTROLLER ACTUATOR HYDRAULIC
SYSTEM
remote pressure control in
pipeline (7), would disrupt
feedback and override the ∆p Controlled
Variable Qp
primary function of the FEEDBACK
(lines 4,7)
regulator.
Qp X Fig. 5.21. Block diagram of the flow

regulator
Flow
module
Pump Hydraulic circuit diagram for variable

module
displacement pump with flow control is
shown in Fig. 5.22
Fig. 5.22. Flow control circuit

REMOTE FLOW CONTROL
Manual remote flow control arrangement is shown in Fig. 5.23.
Instead of an adjustable throttle (6) in 8

Fig. 5.20, pressure drop is created by ps
metering manual 4/3 DCV (7). The
pressure lines between DCV and
cylinder are connected via shuttle valve 5 x
(8) to the pump flow control module (5).
7
When the operator moves the spool in

the DCV say 20% of its stroke, the slot Q
p
on the spool land creates pressure
drop ∆p = p − pS , which acts on the
proportional spool of the flow control
module (5). The flow control module
varies pump displacement to maintain
pressure drop ∆p = const according to
its setting and therefore, flow rate and Fig. 5.23. Manual remote flow control
cylinder speed remain constant.
In applications where pump drive speed is constant, another remote flow

control arrangement is to control pump displacement directly - Fig. 5.24:
2 – Control pump to supply pressure to ps 5
regulator independently of system pressure 4
P X2 6
5 – Pressure reducing valve for remote
control of the position of the proportional 3
Qp
spool (6)
B 8
8 – Mechanical feedback to maintain
position of the control cylinder (9) 2
SwP 9
1
proportional to the position of the
proportional spool (6)
SwP – Swash plate displacement. Fig. 5.24. Remote displacement
delivery control
Remote
setting (5)
Qp
Displacement remote control is
Setting Pc
CONTROLLER ACTUATOR HYDRAULIC the closed-loop proportional
SYSTEM
control system with mechanical
Controlled Variable
feedback – Fig. 5.25. This control
SwP method is not as accurate as flow
FEEDBACK
(link 8)
control (load sensing). Therefore,
its main application is for high flow
rates, where pressure drop across
Fig. 5.25. Block diagram of the an adjustable throttle results in
displacement regulator significant power loss.

COMBINED PRESSURE AND FLOW CONTROLS
Both pressure and flow control modules can be Qp

used together – Fig. 5.26. From point 1 to point 3 1 2 3
Q1
flow regulator operates to control set flow Q1,
and from point 3 to point 5 pressure regulator
4
overrides flow control to control set pressure p1.
5
p1 ps
Fig. 5.26. Pressure-flow
control graph
ps
Principle of the combined regulator
operation is shown in Fig. 5.27. Flow
control module and pressure control
module are installed in series. If flow rate
Q increases above its setting, the
Q proportional spool in the flow control
module will reduce control pressure pc
and, therefore, pump displacement.
pc
However, if system pressure ps
increases above its setting, the
proportional spool in the pressure control
module will further reduce the pump
displacement.
ps
Fig. 5.27. Pressure-flow control

Q Flow
module
Pressure
Hydraulic circuit diagram for module
variable displacement pump with
combined control is shown in
Fig. 5.28 Pump
module
Fig. 5.28. Pressure-flow control circuit

EXAMPLE 5.1. Hydraulic system for molding press

To increase efficiency of the hydraulic system for a molding press using a multi-
pump circuit, consider possible solution of the problem by using pump delivery
control.
To provide fast approach with low pressure and slow final pressing with high
pressure, a variable displacement pump with pressure-flow control is installed in
the system – Fig. 5.29:
6 – Adjustable throttle 1
8 – Safety relief valve
9 – Solenoid On-Off valve
15 – Flow control module 10
16 – Pressure control module 11
17 – Mechanical stop S1 S2
The mechanical stop (17) is 9 p1

adjusted to achieve the required
15
cylinder speed during step 1 (fast S3
approach). 6
During step 2 (final pressing) the Q 16

p
solenoid S3 is energized, and the
flow control module (15) provides
the required flow rate Q = 6 L/min 1 17
8
(1.6 GPM).
Pressure control module (16)

maintains the required pressure Fig. 5.29. Hydraulic circuit for molding press
for step 3 (holding) with variable displacement pump and
pressure-flow control
The efficiency of the described system during step 2 is similar to the multi-pump
system. However, the system with variable displacement pump has the
following advantages:
• Pump delivery for step 1 can be tuned exactly according to the required
cylinder speed (up to maximum pump delivery)
• Additional functions for pump delivery control can be used. For example,
in the system shown in Fig. 5.29 the pressure control module (16) must
have a pressure setting above the maximum pressure required during
step 3 (holding) to provide pressure drop across the throttle (6) during
step 2. If this condition is unacceptable, additional remote pressure
control can be installed to enable setting of the holding pressure exactly
to specification.

POWER CONTROL
Power control sets a power limit that is a Qp 1 4
combination of pump displacement and
Pressure
operating pressure ps * Vg = constant. control
With constant drive speed, it means 2
Power
control
ps * Qp = const – Fig 5.30. The power
control provides a curve with hyperbolic 3
characteristic. Increasing of system pressure Flow control
ps causes decreasing of Qp (points 1 – 2 – 3).

Any point at parabolic curve follows the rule: ps
p1 × Q1 = p 2 × Q 2 = p3 × Q3 = const Fig. 5.30. Power control graph
This control has two important advantages:
• It significantly reduces the size of the prime mover

• It provides a smooth transition from high flow (point 1) to low flow (point 3)
Note. Regulator dynamic response, when moving from point 1 to point 3,

will be close to the curve 1 – 2 – 3. If pressure and flow control is used, it
is difficult to predict step response. In the worst case scenario, the
movement can be 1 – 4 – 3.
Principle of operation of the power Qp 5

regulator is shown in Fig. 5.31. System
6
pressure ps acts on the plunger (4) and
creates a force on the proportional spool ps 8
(6) via mechanical link (8). The force acts
on the proportional spool against spring (5).
Therefore, spool displacement and control pc
pressure pc are proportional to the force. 9
For the same system pressure ps the SwP

amount of force acting on the spool (6)
depends on the position of the control 1 2 3 4
piston (3): the larger swash plate
displacement, the larger the force.
Fig. 5.31. Rexroth LR2 power control
Finally, the swash plate position SwP (i.e. pump displacement Vg) is
proportional to the control pressure pc. This provides output hydraulic power
proportional to the product of ps and pump displacement Vg. Setting of the
spring (5) determines static position of the spool (6), pressure pc, swash plate
position SwP, and pump delivery QP.

Power regulator is a closed-loop proportional control system with the feedback

signal proportional to product of system pressure ps and pump displacement
Vg – Fig. 5.32.
Drive
speed
Setting Pc SwP Qp
CONTROL HYDRAULIC
CONTROLLER PUMP
PISTON SYSTEM
Vg
PsxVg Controlled
Variables Ps
FEEDBACK
Fig. 5.32. Block diagram of the power regulator
Pressure control module can be

included to control maximum system
Qp
pressure ps – Fig. 5.33
Pressure control module (7) overrides ps

power control, when the set pressure
is reached. pc 7
Block diagram of the regulator is Fig. 5.33. Rexroth LR2D power and
shown in Fig. 5.34. pressure control
PRESSURE
FEEDBACK
Ps
Setting Pc SwP Qp Ps
CONTROL HYDRAULIC
CONTROLLER PUMP
PISTON SYSTEM
Vg Controlled
PsxVg Variables
POWER Ps
FEEDBACK
Fig. 5.34. Block diagram of the power regulator with pressure control
EXAMPLE 5.2. Hydraulic system for molding press
Hydraulic system with variable displacement pump (Example 5.1) can be further
developed by using power control with additional control functions – Fig. 5.35.
20
10
11
2 – Control pump S1 S2 15
5 – Control pressure 7 Qp
reducing valve
14
9 – Control ON-OFF
solenoid valve
14 – Hydraulic stroke 9 S3
5
limiter (remotely controls pr
16
maximum pump delivery)
15 – Pressure control
module pc
p2
17 – Mechanical stroke Q2 ps
limiter 17
1
2 12
Fig. 5.35. Hydraulic system for molding press with power

control, pressure control, and stroke limiters
The following settings are applied:
• Power control module is adjusted to limit hydraulic power to 7 kW (10 HP)

• Mechanical stop (17) is adjusted to provide pump delivery 72 L/min (19 GPM)
for step 1
• Pressure control module (15) is adjusted to limit maximum system pressure for
step 3
• Reducing valve (5) is adjusted to provide pump delivery 6 L/min (1.6 GPM) for
step 2
During step 1 (fast approach), pump delivery (power) control provides stepless
deceleration of cylinder speed as load-induced pressure increases – without
power losses. During step 2, solenoid (9) is energized, and pump delivery
provides accurate cylinder speed control without power losses. During step 3,
pressure control module (15) reduces the pump displacement to minimum
required to maintain the holding pressure.
The advantages of power control in the described application are obvious.

Disadvantages of power control:
• Higher initial cost of the regulator
• Higher cost of maintenance

ELECTRO-HYDRAULIC CONTROL
Pump delivery control can be part of an electro-hydraulic proportional
control system. Such arrangement can be used for both functions of closed-
loop proportional control:
• A follow-up system (servo Control

input
system), where the electrical CONTROLLER
PUMP
DELIVERY
HYDRAULIC
SYSTEM
input signal is constantly
changing, and the output Controlled
(controlled variable) is variable
FEEDBACK
controlled to follow the input
(Fig. 5.36)
Fig. 5.36. Block diagram of a servo system
• A regulator, where the

Setting
function of the system is CONTROLLER
PUMP HYDRAULIC
DELIVERY SYSTEM
maintaining the controlled
variable at a set value, and Controlled
electrical control signal variable
FEEDBACK
changes setting (Fig. 5.37)
Fig. 5.37. Block diagram of a regulator
To simplify analysis, consider possible options for electro-hydraulic control of

the system pressure based on the variable displacement pump. All options are
applicable for control of many different parameters (flow, power, etc).
Consider remote pressure control of the variable displacement pump (see

Fig. 5.16). This is a hydraulic closed-loop system with function to control system
pressure according to the setting, i.e. pressure regulator – Fig. 5.38. The
closed loop here is: proportional spool – pump displacement – system
pressure – feedback line.
4 Manual
Input Pc
RELIEF PROPORTIONAL CONTROL
x VALVE (4) SPOOL (3) PISTON (2)
3
SwP
Qp
HYDRAULIC
12 FEEDBACK PUMP (1)
ps (12)
Qp
Output -
Force Ps
HYDRAULIC
CYLINDER
SYSTEM
1 2
Fig. 5.38. Remote pressure control
OPTION 1.

Electro-hydraulic pressure regulator can be configured by replacing the

conventional pressure relief valve (4) in Fig. 5.38 with a proportional pressure
relief valve (5). The regulator provides reasonably accurate control of the
hydraulic system pressure according to setting of the input electrical signal –
Fig. 5.39.
5
x • 2 – delivery control piston
3 • 3 – proportional spool
• 5 – proportional pressure relief
Qp valve
• 12 – pressure feedback
ps 12
1 2
Block diagram of the regulator is

Fig. 5.39. Electro-hydraulic pressure shown in Fig. 5.40. Input electrical
regulator signal can be generated by any
programmer or manually.
The main problem with this Input p5 pc

arrangement is double PROPORTIONAL PROPORTIONAL
SPOOL (3)
CONTROL
VALVE (5) PISTON (2)
conversion of the signal:
SwP
1) Input electrical signal
HYDRAULIC
into proportional set FEEDBACK PUMP (1)
pressure p5 (12)
Qp
2) Set pressure p5 into
Output -
Force ps
HYDRAULIC
proportional control CYLINDER
SYSTEM
pressure pc
Fig. 5.40. Block diagram of pressure regulator
Therefore, accuracy of such control is within 5%. Dynamic response is very

slow with possible oscillation.
Possible applications:
• Manual changing of the set pressure
• Electro-hydraulic sequential control, when dynamic response is not
critical

OPTION 2.
For proportional follow-up pressure control with high accuracy and good
dynamic response the solution is to use servo control with internal feedback
through swash plate position transducer. In this arrangement the pump control
includes an electro-hydraulic proportional valve (4) and pump
displacement transducer (9) – Fig. 5.41.
• 6 – Control pump to
provide independent 8 u
ps
hydraulic supply for
proportional valve (7) 10
7
• 7 – Proportional valve Qp Controller
• 8 – Pressure transducer Ps
for main feedback
• 9 – Control piston u Programmer
s
displacement transducer 6
• 10 – Electronic card to 9
1 2
provide internal feedback
via transducer 9
Fig. 5.41. Follow-up pressure control system
Block diagram of the system is shown in Fig. 5.42.
Input Pc
AMPLIFIER PROPORTIONAL CONTROL
CONTROLLER PISTON (2) PUMP (1)
(10) VALVE (7)
Qp
SwP
TRANSDUCER HYDRAULIC
(9) SYSTEM
Ps
TRANSDUCER
(8)
Output -
Force
CYLINDER
Fig. 5.42. Block diagram of follow-up pressure control system
From the point of view of pump displacement control this is the best option,
because it provides precise and repeatable control of the swash plate angle
independently of the force generated on the swash plate by the pump’s rotating
cylinder block. Moreover, fine tuning of the amplifier (10) will give smooth and
fast dynamic response of the control system. Accuracy of the pressure control is
achieved by main feedback (8) with the fine tuning of the controller. It is not
affected by internal leaks in the pump, speed of pump rotation or any other
system disturbances.

OPTION 3.
u
High accuracy of control is F
achieved by using main feedback
of the controlled mechanical
8
parameter (here, the force created
by the cylinder) – Fig. 5.43.
The electronic controller gives the
command to the proportional valve 10
Qp 7
based on the error in the closed- Controller
Ps
loop system (difference between
input signal and actual output – u Programmer
s
force). 6
1 2 9
Fig. 5.43. Follow-up force control system
Block diagram of the system is shown in Fig. 5.44
Input Pc
AMPLIFIER PROPORTIONAL CONTROL
CONTROLLER PISTON (2) PUMP (1)
(10) VALVE (7)
Qp
SwP
TRANSDUCER TRANSDUCER HYDRAULIC

(8) (9) SYSTEM
Ps
Output -
Force
CYLINDER
Fig. 5.44. Block diagram of follow-up force control system
Output of the system depends on the main feedback transducer (8). It could be
actuator force, or displacement, or speed, or torque of a hydraulic motor, etc
Advantages:
• Direct control of the output mechanical parameters (force instead of

pressure, speed instead of flow rate, etc)
• High accuracy of control
• Replacement of hydraulic regulator with electronic regulator
• Substantial reduction in the number of hydraulic valves and therefore,
simplification of maintenance and troubleshooting

FURTHER READING
‘Advanced Hydraulic Control’ by Brendan Casey & Marian Tumarkin

Available second half of 2007: http://www.HydraulicSupermarket.com/books

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How to Understand

Copyright © 2007 Brendan Casey & Marian Tumarkin

All rights reserved. No part of this electronic book may be reproduced or

First published in 2006 by

About the Authors

Brendan Casey is the founder of HydraulicSupermarket.com and the best-

A highly experienced Fluid Power engineer, Marian has designed electro-

Marian has extensive teaching experience both in Europe and Australia,

Copyright © 2007 ─ www.HydraulicSupermarket.com

PUMP DELIVERY CONTROL

• Delivery control of the fixed-displacement pump by changing the speed

The second method is widely used. Adjustment of pump displacement is

For example, in a variable-displacement vane pump, control pressure moves

The types of control methods are

Main components of a variable- 5 4 3

Copyright © 2007 ─ www.HydraulicSupermarket.com

A variable pump regulator is essentially a Control Piston

The regulator circuit diagram uses common

Fig. 5.3. Rexroth pump A4VSO

Fig. 5.4. Pump module with

Two control pistons can be used to simplify

The pump module is an actuator (Fig. 5.6) for a closed-loop proportional

Fig. 5.6. Block diagram of the pump module

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Fig. 5.11. Block diagram of the pump delivery regulator

Important features of the regulator are:

• Controlled variable is measured directly (system pressure) or with a

• Two or more variables can be controlled by the regulator, but not

• Setting options can be manually, directly on the pump, or remotely from

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PRESSURE AND FLOW CONTROL

Function of the pressure regulator is to control system pressure ps according

therefore system pressure ps from point 2 p1 ps

through connection (4) on the proportional

The pressure regulator is a closed- Qp

Hydraulic circuit diagram for variable

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REMOTE PRESSURE CONTROL

Remote pump delivery control is required in two situations:

Remote pressure control arrangement is 7

Fig. 5.17. Block diagram of pressure

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FLOW CONTROL (LOAD SENSING)

The flow regulator is a closed-loop

Qp X Fig. 5.21. Block diagram of the flow

Pump Hydraulic circuit diagram for variable

Fig. 5.22. Flow control circuit

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REMOTE FLOW CONTROL

Manual remote flow control arrangement is shown in Fig. 5.23.

Instead of an adjustable throttle (6) in 8

When the operator moves the spool in

In applications where pump drive speed is constant, another remote flow

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COMBINED PRESSURE AND FLOW CONTROLS

Both pressure and flow control modules can be Qp

Fig. 5.27. Pressure-flow control

Fig. 5.28. Pressure-flow control circuit

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EXAMPLE 5.1. Hydraulic system for molding press

The mechanical stop (17) is 9 p1

During step 2 (final pressing) the Q 16