Design of Flow and Pressure Coupling Controller for

Independent Metering Valves Control System

Bin Zhang, Shuang Wang, Yuting Liu, Qi Zhong, Huayong Yang

The State Key Laboratory of Fluid Power Transmission and Control
Zhejiang University
Hangzhou, China
Email: zbzju@163.com

Abstract— Compared with traditional valves control system,
independent metering valves control system (IMVCS) broke
down the mechanical coupling of the meter-in and meter-out
orifices, so that it increased the control degrees of freedom.
Usually two spools were used to determine one actuator’s state in
IMVCS. The key difficulty was to coordinate the opening
displacement of two spools that can output pressure and flow
according to control strategy. This paper introduced the
components and working principle of IMVCS. A flow and
pressure coupling controller was designed to control both velocity
of piston and pressure in each chamber. A SYS/BIOS based
embedded operating system was adopted for fast response. Large
set of sensors can be integrated which their amplifying circuits
were designed on board. The IMVCS used dual close loop control
to monitor and modify pressure and flow in real-time. Four types
of threads were provided to schedule tasks. The real-time
multitasking control software was developed. To verify the
control strategy and PCB'A, a preliminary experiment showed
the results of step response and sine signal tracking that two
spools worked by onboard controller.
Keywords—proportional valve; independent metering; flow and
pressure controller; coupling control
I. INTRODUCTION
As one of the most important control components in
hydraulic system, hydraulic valves are responsible for the
control functions of the entire system. Traditional hydraulic
valves only have one spool to regulate an actuator’s pressure
and flow of inlet and outlet. This structure has disadvantage for
control inflexible and high energy consumption. In recent
years, a kind of valves control technology called independent
metering valves control system (IMVCS) became a hotspot on
research. IMVCS broke down the mechanical coupling of the
meter-in and meter-out orifices so that it increased the control
degrees of freedom. Jan Ove Palmberg from Linköping
University first proposed the concept "Separate controls of
meter-in and meter-out orifices" [1] according to the cartridge
valve control theory presented by professor Backé [2]. In their
later research, LQG optimal control method is adopted to
decouple the different pressure in each chamber of actuator [3].
Purdue University studied the tracking and energy saving
performance by applying robust adaptive control strategy. Five
poppet valves were used. Four of them was to realize the
function of independent metering control and one was for flow
regeneration [4]. Dresden University of Technology put effort
on independent metering structure of valves. Parallel and series
arrangements were discussed. The parameters in actuator
influenced the performance as well [5]. Matti Linjama from
Tampere University of Technology used a certain number of
high-speed switching valves to implement parallel connected
digital hydraulic system which called DFCU. Control method,
reduction of pressure peaks, fault detection and compensation
were considered [6]. Amir Shenouda from Georgia Institute of
Technology used INCOVA supported by HUSCO to build
control system placed proximal actuator. Research focused on
the energy savings potential of the four valves independent
metering configuration in addition to improving performance
[7]. Zhejiang University investigated the multi-mode control
method of IMVCS. NLPQL optimization method was tested by
experiment to improve the precision and efficiency [8].
Central South University used ZTS16 twin spools valve from
Eaton to achieve application on excavator [9].
Compared with traditional valves and valves control system,
IMVCS has many advantages [10], see Figure 1.
• Reducing throttle loss.
• Flexible configuration of the hydraulic circuit.
• Improve control performance and energy saving.
• High versatility of components.

The “Twelfth Five-Year” National Science and Technology Support

Program of China (No.2014BAF02B00).
978-1-5090-6190-7/16/$31.00 ©2016 IEEE

Fig. 1: Traditional valves system (left) and IMVCS (right)
The research mention above almost used PC as controller.
For an engineering application, an embedded control system is
necessary. This paper was focused on independent metering
valves control system. The control strategy of pressure and
calculation flow feedback were built. The DSP and sensors
were selected. The related circuit principle and manufacture
PCB'A were designed. Based on SYS/BIOS embedded
operation system, the real-time multitasking control software
was developed. Through the step response and sine signal
tracking experiments, control problems were discussed and the
optimization scheme was put forward.
II. INDEPENDENT METERING VALVES CONTROL SYSTEM
The IMVCS consists of a controller, a displacement pump,
a twin spools electro-hydraulic proportional directional valve,
an electro-hydraulic proportional relief valve, pressure sensors,
LVDT displacement sensors, a cylinder used as actuator and
load, see Figure 2.
Fig. 2: Components and connection of IMVCS
The pressure sensors placed proximal actuator detect the
pressure values and give feedbacks to controller. The controller
selects control mode according to working condition so that
displacement pump can realize the function called "Load
Sensing", which means the supply pressure is little higher than
load needed through adjusting the electro-hydraulic
proportional relief valve. It can greatly reduce the energy
consumption. Meanwhile, the twin spools receive control
signal and determine the opening displacement of each spool.
The inlet and outlet flow are calculated by spool pressure drops
and displacements. The input signals are four kinds of pressure,
two displacements and the temperature of hydraulic oil. The
output signals are two PWM signals given to two spools. CAN
bus is used for electrical interface integrated.
Fig. 3: Block diagram of Flow and Pressure
Coupling Control
Figure 3 shows the flow and pressure coupling control
strategy. Pressure feedbacks are faster than flow feedbacks.
Therefore, pressure control is inner loop whereas flow control
is outer loop. Considering flow through one spool causes the
pressure change in chamber, flow decouple algorithms for two
spools are adopted.
The inlet and outlet flow is calculated by values of pressure
sensors and LVDT displacement sensors according to the
equation:
2ΔP
Q = Cd A
ρ (1)
Where Cd is flow coefficient and A is orifice area. These
parameters are related to displacement, X V . For more accurate,
the temperature of hydraulic oil is regarded. If flow through
spools is calibrated, a two-dimension table can be used in
software to explicit the relationship between X V , T and Cd , A .
The function fQ is to mark. The equation can be written as:
2 ΔP
Q* = f Q ( x v , T )
ρ (2)
The parameters of hydraulic system are as bellows:
 • Rated Pressure: 35MPa • Accuracy: f0.1ć
• Rated Flow: 130L/min • Voltage: 24V DC input/ 0~5V DC output
• Pilot Pressure: 2MPa • Withstand Pressure: 40MPa
• Spool Stroke: f4mm
C. Proportional valve drive module
• Electrical Interface: CAN BUS The spool is driven by Voice Coil Motor. It has characters
• Drive Voltage: 24V DC\32V DC\3.3V DC of small size, high acceleration, and fast response. The voice
coil motors selected:
• Diameter: 40mm
III. FLOW AND PRESSURE CONTROLLER FOR IMVCS • Effective Stroke: 1.5mm
The IMVCS controller is designed within the constraints of • Drive Voltage: 32V DC
embedded system. The main parts are DSP core, amplifying
circuit of sensors, proportional valve drive module and power • Continuous Output Force: 25N
management module. To accomplish spool switching, bipolar "H" type PWM
changing circuit is applied, see Figure 4.
A. DSP Core
As the flow calculation is proceeded in valves controller, a
fast control core is necessary. An appropriate DSP is the most
important. TMS320F28335 from TI INC. is selected. Its clock
frequency is 150MHz with the ability of Floating Point Unit
(FPU) [11].
• Drive Voltage: 3.3V DC
• Flash: 256Kh16
• SARAM: 34Kh16
Some peripherals that concerned are 16-channel 12-bit
ADC (analog-to-digital converter) which transfer time less than
80ns, 18 enhanced EPWM outputs, and two CAN BUS
modules.
Fig. 4: bipolar "H" type PWM changing circuit
B. Sensors
The sputtered thin film strain gauge technology provides The drive circuit receives two adverse PWM signals. When
excellent stability pressure rate. Wheatstone bridge is used. duty ratio is 50%, two signals offset each. The voice coil motor
output is null. When duty ratio is not equal 50%, the average
• Range: 0~42MPa voltage determine the direction and values.
• Accuracy: f0.5%
D. Power management
• Voltage: 24V DC input/ 0~5V DC output As described above, there are three kinds of voltage in the
controller. The input voltage and sensors driven are 24V DC.
• Frequency response: 1KHz
The control of voice coil motors needs 36V DC, so a boost
Linear Variable Different Transformer (LVDT) is adopted circuit is needed. 3.3V DC is for DSP and peripheral interfaces.
to sample the displacement of spool. The controller is integrated and PCB'A is made, see Figure 5.
• Range: f4mm
• Accuracy: f0.5%
• Voltage: 24V DC input/ 0~5V DC output
• Frequency response: 200Hz
Standard platinum resistance thermometer (SPRT) makes
the resistance changing in a linear fashion according to
temperature.
• Range: -20~85ć
 8. Timed cycle thread: clk_spool1Fxn, clk_spool2Fxn,
clk_flow1Fxn, clk_flow2Fxn, clk_pressure1Fxn,
clk_pressure2Fxn
This kind of threads are signaled by periodic time interval.
The threads name are corresponding with "task" threads. When
control parameters change, timed cycle threads trigger software
interrupts.

TABLE I. THREAD TYPES AND PRIORITIES

Fig. 5: PCB'A of IMVCS controller Thread

Priorities
Types
The operate system is based on SYS/BIOS [12]. It is a
Emergency stop thread
multitasking platform especially designed for DSP and ARM. Hwi
There are four types of threads. From highest to lowest priority, Hwi_receiveFxn
they are Hwi (Hardware Interrupts), Swi (Software Interrupts), clk_spool1Fxn, clk_spool2Fxn,
Task (which it has 32 sub-priorities), Idle. Swi clk_flow1Fxn, clk_flow2Fxn,
clk_pressure1Fxn, clk_pressure2Fxn
According to the control strategy mentioned in Chapter II, task_spool1Fxn, task_spool2Fxn
the software of flow and pressure coupling control for IMVCS Task task_flow1Fxn, task_flow2Fxn
is programmed. task_pressure1Fxn, task_pressure2Fxn
Error self test thread
Idle
Idle_Fxn
1. Upload thread: Idle_Fxn
Monitor and upload valve parameters when in idle,
including supply pressure, tank pressure, hydraulic oil IV. PRELIMINARY EXPERIMENT RESULTS
temperature, displacement of spools, PWM values, et at. The An experiment test rig is built to verify the control strategy
data link and transmission should comply with the CAN BUS and on board controller. ZTS16 twin spools valve is
communication protocol and coding. implemented for independent metering control.

2. Download thread: Hwi_receiveFxn

Download control parameters and trigger a hardware
interrupt.

3. Emergency stop thread

The highest priority thread. When the parameters are wrong,
the duty ratio of all valves PWM signals force to be 50%. To
avoid impact, a ramp signal to 50% will give if the load is too
heavy.

4. Error self test thread

Parameters self-test when in idle. If abnormal, alarm or
Fig. 6: Independent metering control test rig
trigger emergency thread.
On the basis of control strategy, step response and sine
5. Control thread of spools displacement: task_spool1Fxn, signal tracking are conducted.
task_spool2Fxn

6. Control thread of flow: task_flow1Fxn, task_flow2Fxn

7. Control thread of pressure drop: task_pressure1Fxn,

task_pressure2Fxn
These three threads are task thread to realize the main
function of IMVCS.
A. Step response
Fig. 7: The step response of two spools in IMVCS
As is shown in Figure 7, a step signal is given. Spool 1 has
a 0.2mm to 2.2mm step in 52ms. Meanwhile, spool 2 has a -
1mm to -1.5mm step in 46.2ms. It is precisely because IMVCS
is adopted, the two spools can have different displacements.
The valve has overlap, so there is no flow in the displacement
of f1mm.
Fig. 8: 2Hz sine signal tracking experiment
Figure 8 shows the experiments that IMVCS tracks a 2Hz
sine signal. It can perform well even if there is only one spool.
The IMVCS can also work separately if necessary which
doubles the numbers of valve components.
V. CONCLUSION
Although lots of research have been done about independent
metering valves control system, the control strategy and
application still need efforts. From hardware to software, a
controller is designed using flow and pressure coupling control
strategy. An embedded system based on SYS/BIOS and DSP
helps to plan real-time multitasking. The experiments show the
step response and signal tracking results. Further study will
concentrate on multi-actuators control and energy saving.
ACKNOWLEDGMENT
This work was funded by the “Twelfth Five-Year” National
Science and Technology Support Program of China
(No.2014BAF02B00).
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