Term Paper

Low Cost Automation- MEL 334

Proportional Valves

Submitted by: Kanav Mahajan 2009ME20664 Yush Raj 2009ME20688

Proportional Valves
Hydraulic valves that are electrically operated by proportional solenoids are classified as proportional valves. These are of various types: proportional directional control, proportional relief, proportional pressure reducing, proportional flow control, and proportional throttle valves. The function of proportional valves is to provide a smooth and continuous variation in flow or pressure in response to an electrical input. In these valves, it is important to link the electronics to the valve very carefully. In general proportional valves find most of their applications in open loops situations where pressure and flow are required to change continuously, where multiple fixed flow and pressure valves can be replaced by a single valve and where acceleration and deceleration under control are required. The key to the operation of a proportional valve is a balance established between the forces in action on the plunger. These balanced forces include a mechanical force provided by a spring specially developed for proportional valves and a magnetic force created by the current level passing through the coil. The spring force is proportionally opposed by the magnetic force.

1 2 3

Coil Spring Plunger

4. Magnetic field

As can be seen in the above picture, we can balance the solenoid armature force with an external spring. The spring will compress until the force of the spring is equal to the armature force (a stable position). Increasing the current, increases the armature force resulting in an imbalance force on the spring, which compresses the spring until a balance is re-established.

Power supply Often, one hears that proportional valves react proportionally to the voltage supplied. However, in practice, the current passing through the valve will heat the coil and eventually increase the internal resistance. At constant voltage, increasing the resistance will provoke a current drop and thus a drop of the magnetic force. As a result, the valve will tend to slowly close. To avoid this problem, one can use a stabilized current supply. The current supply will be independent of the coil resistance. The only draw-back is that such a device is more expensive than a voltage supply. Sealing To ensure a positive shut-off when the valve is de-energized, there is always a voltage/current offset before obtaining a flow (liftoff point).

Control Usually, a closed control loop circuit and a pressure (or flow) sensor are used with the power supply. If high precision is not an issue, one can also use an open control loop

Types
1. Proportional direction control valves Standard directional proportional valves are perfect for many hydraulics applications. There are low cost designs without spool feedback for manual and open loop control applications. These can be direct or pilot operated. General purpose valves have better axis performance and accuracy, and Rexroth has implemented valve design improvements that have reduced cost. Consequently, these standard proportional directional valves work well in many closed loop applications.

2. Proportional flow control valves Electronically adjusted orifices with pressure compensation, proportional flow control valves have an integrated compressor or hydrostatic that limits the pressure differential across the throttling orifice. This keeps the flow, or actuator speed, constant when the load forces change. Its one more example of how Rexroth intelligent hydraulics lets you optimize machine and assembly line performance and protect manufacturers investments in manufacturing technology.

3. Proportional pressure relief valves Proportional pressure relief valves limit the pressure in a hydraulic circuit and allow this set limit to be adjusted by electronic control. While relieving pressure, excess flow is returned to a hydraulic reservoir tank, to improve machine efficiency and manufacturing productivity. 4. Proportional pressure reduction valves By regulating downstream pressure in a branch circuit, proportional pressure reducing valves allow this set limit to be adjusted by electronic control. Rexroth reducing valves are optimized to reduce the effect of pressure changes due to varying flow rates. Their excellent transient response prevents excess pressure or overshoot, and under pressure, during changes in desired pressure conditions. Very low pressures can be accurately controlled. In addition, they continue to operate correctly if the flow becomes static. Rexroth proportional reducing valves provides a wide range of flow capacity in pressure control functions.

Proportional valves are well suited for circuits that need to vary either flow or pressure to reduce lunge and shock. The solenoids on these valves shift the spool more or less, According to the voltage applied to proportional solenoids, they can change the speed at which the spool shifts or the distance that it travels. Because the spool in a proportional valve does not shift all the way, all at once, the valves can control the acceleration and deceleration of an actuator. Usually, varying shifting time of the spool controls acceleration and deceleration. Varying voltage to the coil limits spool travel to control the maximum speed of an actuator. A computer, a PC, a programmable logic controller, or even a simple rheostat can produce the variable electric signal.

Proportional directional control valves are more tolerant of contamination and cost less than the servo valves that they often replace. When a circuit does not require extreme accuracy or flow repeatability, the savings in first cost, plus a less-expensive filtration requirement, make proportional valves a good choice. One reason a servo system is more accurate is the electronic feedback signal from the actuator. The feedback signal modifies the servo valves spool position to put the actuator in an exact place, or produce the speed or force that the controller requires. A proportional valve may have feedback control, but the response time of the valve is too slow to get the precise control that a servo valve circuit provides.

Use proportional control valves to reduce shock and give a finer degree of control to circuits that do not require extreme position accuracy, or repeatable speed and force. Proportional valves restrict flow to and from an actuator. They work best with a pressurecompensated pump in a closed-center circuit. An accumulator in the circuit enhances cycle response time and protects the pump from pressure spikes. Systems that use proportional valves usually require a heat exchanger because energy waste is higher with this type circuit.

Figure (a)
A proportional throttle valve in the pump line of the figure above controls flow to a standard solenoid valve. This circuit is good for resistive loads only because it meters fluid to the cylinder. To reduce energy waste a load-sensing pump is used and the line between the proportional valve and the directional valve is sensed. Load sensing lets the system operate at lower pressures during most of the cycle. Load sensing also makes the circuit pressure compensated.

The proportional throttle valve in the figure below meters flow out of the tank line of a standard solenoid valve. This circuit is good for over-running loads because it meters fluid from the cylinder. CAUTION: The directional valve may see pressure as high as twice the pump compensator setting. Make sure this pressure does not exceed its tank line rating. Allowing the throttle valve to shift abruptly in this meter-out circuit could result in detrimental shock. Here we need to use a proportional control card with adjustable ramps for this application.

Figure (b)

The circuits in Figures (a) and (b) control acceleration and deceleration of an actuator. Electronic signals to these circuits also can vary the speed of the actuators infinitely.

References

1. http://forums.hydraulicspneumatics.com/eve/forums/a/tpc/f/5821030121/m/2061094412 2. http://www.boschrexroth.com/country_units/america/united_states/sub_websites/brus_brh_i
/en/products_ss/08_proportional_servo_valves/a_downloads/ra29158_0405.pdf 3. http://www.samson.de/pdf_en/t60000en.pdf 4. http://www.fas.ch/info_tech_prop.asp?sectionID=t&Langue=english

5. http://www.iranfluidpower.com/pdf/All%20hydraulics/Proportional%20Valves.pdf 6. http://hydraulicspneumatics.com/other-technologies/book-2-chapter-14-proportional-controlvalves

FAQs 1. 2. 3. 4. 5. What are proportional valves? What are the functions? What are their basis of operation Why and where are they needed? ( comparison with servo valves) Any disadvantages?