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In this study, a new high frequency three way proportional pressure-reducing valve has been developed. By reducing
the turns of the coil and using a high speed current amplifier, the responding time of the proportional solenoid is reduced to
less than 1 ms. The steady and dynamic analyses show that the output pressure is proportional to the coil current and the
dynamic bandwidth can be increased by increasing the coil current. An experimental system is built up and results well
agreed with the theoretical and simulation analyses. The bandwidth of the valve is about 130 Hz at -3dB, which can meet the
demand of automobile engine with maximum speed of 3000 rpm.
Keywords: High frequency, Proportional pressure reducing valve, Variable valve, Proportional amplifier, Simulation
The conventional mechanism of valve in automobile of the valve. Then, based on the mathematical model,
engine is driven by cam. This method is difficult to we analyze the steady-state and dynamic performance
meet the demand for high dynamic quality, of the valve. Finally, we carry out experiments to
economical efficiency and environment protection. verify both the analysis and the desired performances
Some research showed that by using variable valve of the valve.
techniques, engine performance can be improved1.
There are three kinds of variable valve systems Structure and Working Principle
including cam system, electromagnetic system and In this paper, a newly developed pressure-reducing
electro-hydraulic system2. Because the adjustable proportional valve with low cost and high
range of cam system is restricted within narrow limits, frequency is employed in the variable valve system
electromagnetic system and electro-hydraulic system show in Fig. 1.
are showing its potential features in industry Figure 1 shows the schematic diagram of electro-
application. In electro-hydraulic system, there is no hydraulic variable valve system. It is easy to see that
cam3; hence the opening and closing processes of the the opening process of valve in the engine is
valve are controlled by a high-speed electromagnetic proportional to the output pressure of the pressure
valve. The response time and the flow rate are two reducing valve. The working principle of the pressure
contradictory parameters for a high-speed electro- reducing valve is shown in Fig. 2. This is a three way
magnetic valve. Many high speed valves have been proportional pressure reducing valve without return
developed for the control of fuel injection4-7. Because spring. The force generated proportional electro-
the variable valve system requires larger flow rate, magnet is balanced by the hydraulic force acted on the
usually servo valves are employed in the system8-10. left side of the spool. Hence, the output pressure Pc
Due to the high cost of servo valves , therefore many can be controlled by the current of the electromagnet.
lower cost, high speed and large flow rate valves are The maximum working stroke of the valve spool is
developed11-13. 0.6 mm, which is beneficial to obtain good
In this study, a low cost, high frequency performance in dynamic response.
proportional pressure-reducing valve was developed.
First, we introduce the schematic diagram of electro- Steady State Analysis of the Valve
hydraulic variable valve system and working principle In order to analyze the effect of the input current on
_________ the steady-state and dynamic performance, the
*For correspondence (E-mail: bjin@zju.edu.cn) mathematical model of the valve was built14-16.
8 INDIAN J. ENG. MATER. SCI., FEBRUARY 2009
Fig.1 — Schematic diagram of electro-hydraulic variable valve system (1-tank; 2-proportional relief valve; 3-hydraulic pump; 4-
proportional pressure-reducing valve; 5-motor; 6-single-rod hydraulic cylinder; 7-return spring; 8-valve)
Ki Ff
Pc = I− … (4)
Av Av
KI
2( Ps − Pc ) Fm = e− ts … (6)
Cd wX v = K c Pc … (1) τ s +1
ρ
The continuity equation of chamber Vc can be
The force balance equation for valve spool can be expressed as:
expressed as following:
Vc dPc dX v
Q1 − Q2 − QL − Cip Pc = − Av … (7)
Fm − Pc Av − Ff − K f X v = 0 … (2) β e dt dt
where
The force output of the solenoid can be expressed as:
QL=0 … (8)
Fm = K i I − K y X v … (3)
C W ( X v − U ) 2( Ps − Pc ) / ρ U < X v ≤ X vmax
Q1 = d
Because the leakage of the valve is very small, from 0 - X vmax ≤ X v ≤ U
Eq. (1), it can be obtained: Xv=0, combine with Eqs … (9)
LIU et al.: PROPORTIONAL PRESSURE REDUCING VALVE 9
Parameter Value
N 100
Xv 0.6 mm
Ps 6 MPa
L 1.2 mH
R 1.2 Ω
I 8.7 A
Mv 0.09 kg
U 12 V
Bv 100 N(m/s)
Dv 8 mm
Digital Simulation of the Valve that the output pressure is proportional to the input
A digital simulation model has been build up using current and has a small dead-band, the results agree
AMESim, the model is shown in Fig. 5 and the well with the results of Eq. (3).
simulation parameters are defined in Table 1. Figure 7 shows the simulation results of step
Figure 6 shows the relationship between output response under the different conditions of I is 4 A,
pressure and input current in steady state, it shows 6 A and 8 A.
LIU et al.: PROPORTIONAL PRESSURE REDUCING VALVE 11
From these figures, the following conclusions can increases with the increase of input current. This
be drawn: (i) there is a delay time between the input phenomenon coincides with Fig. 6, i.e., the larger
signal and the output pressure, which is because of the force moves the spool quicker, hence increase the
overlap of the valve spool; (ii) the delay time will dynamic response. In real applications, this character
decrease with the increases of the input current. will help increase the dynamic response of engine
Because the overlap is a constant value, when the valve; (ii) the overshot of pressure increases with the
current increases the force output will increase, the increase of current; and (iii) the system’s damping is
spool can move faster to overcome the overlap, and low, because the shut off of load.
the overshot increase too. In the real application, the
delay time can be compensated by software ; and Experimental System
(iii) the output pressure is a little bit lack of damping, An experiment system is employed to testify the
this is because the load is cut off (QL=0). In real pressure reducing valve. The block diagram of the
application, the damping will increase significantly. experimental bench is shown in Fig. 9.
From Fig. 8, we can come to the following The experimental bench consists of a low-
conclusions: (i) the cut-off frequency at -3db frequency signal generator, a proportional relief
valve, the PWM amplifier, a pump, a motor, and the
proportional pressure-reducing valve to be tested, a
pressure transducer and an oscilloscope. The output
pressure is measured by the pressure transducer. The
oscilloscope is used to display and store the signals.
Nomenclature
Pc = pressure of port A
I = input current
Xv = spool displacement
Fm = solenoid force
Ki = current-force gain
Ky = displacement-force gain
QL = load flow
Kc = leakage coefficient
Fig. 11 — Experimental results of step response with different Cd = flow coefficient
current w = port width
Ps = system pressure
(i) The output pressure is proportional to the input Kf = steady flow force stiffness
current. Hence, the engine valve lift can be Av = orifice area
changed by varying the input current. Ff = friction force
K = the gain
(ii) The output pressure has a small hysteresis less N = number of turns
than 3%. L = coil inductance
(iii) The valve is lack of damping with the cut off of R = coil resistance
the load. τ = time constant
r = the reluctance
(iv) The dynamic response speed increases with D = outer diameter of the coil
increase in input current, which can help the d = internal diameter of the coil
engine valve act faster with large input. q = sectional area of the wire
LIU et al.: PROPORTIONAL PRESSURE REDUCING VALVE 13