The 11th Asian International Conference on Fluid Machinery and The 3rd Fluid Power Technology Exhibition

Paper ID: AICFM_FP_009 November 21-23, 2011, IIT Madras, Chennai, India

Original Paper

Numerical Analysis on Torque Motor Dynamics used in Electrohydraulic Servovalve

A. S. Sharan1 Somashekhar S. Hiremath2 and C. S. Venkatesh3
1 2

Department of Mechanical Engineering, BIET, Davangere Department of Mechanical Engineering, UBDTCE, Davangere

Department of Mechanical Engineering, IIT Madras

3

Davangere -577004, Karnataka state, sharanas17@yahoo.co.in

Abstract Servovalves are one of the most important electrohydraulic system components that used for controlling the flow direction, volume flow rate, force, pressure, position, speed and acceleration. The electrohydraulic Servovalves have two stages-first-stage includes a torque motor assembly and second-stage is spool valve. The torque motor is an electromechanical transducer used to convert small electric current to a mechanical torque to deflect either a flapper in case of a flapper nozzle valve and a jet pipe in case of a jet pipe servovalve. The dynamics of torque motor plays a crucial role in creating the differential pressure across the spool valve. Hence it is essential to understand torque motor dynamics. The torque motor generally consists of armature, armature coils, permanent magnet, and flapper or jet pipe. The armature is pivoted in between the two permanent magnets. The working clearance (air gap) is provided for the armature deflection is the main parameter in the dynamics. The mathematical model is available in many text books like Merritt, Watton and Blackburn. Also some of the literatures were also available in modeling the torque motor. In the present paper the mathematical model of torque motor proposed by many researchers were considered to analyse the torque motor dynamics and to investigate the influence of magnetic fluids on the dynamic characteristics. The results include variation of torque and jet pipe deflection with input current and discuss the time and frequency response of the torque motor. Keywords: servovalve; torque motor, air gap; flux density, magnetic fluid; torque motor dynamics.

Accepted for publication

(Paper ID: AICFM_FP_009)

Corresponding author: A. S. Sharan, Department of Mechanical Engineering, BIET Email: sharanas17@yahoo.co.in

1. Introduction
The control of electrohydraulic systems has drawing many attentions from researchers for many years. The electrohydraulic systems are considered for testing the performance of newly developed control techniques since their highly nonlinear characteristics. Also, electrohydraulic components are commonly used in many engineering applications [15]. Servovalves are manufactured with very narrow tolerances, thus the cost and significance of Servovalves are higher compared to other electrohydraulic system components. Servo valves include single-, double-, and triple stage valves; two-staged servo valves are most commonly used. In a two-staged servo valve, the first stage transfers electric input to mechanical displacement of a pilot stage valve; the second stage is a spool valve or other fluid control element. Commonly known pilot stage valves are nozzleflapper valve and jet pipe valves [6]. Servovalves are used in control applications where precision and reliability has greater importance such as planes, space vehicles, CNC tools, special test machines, motion simulators, military equipments The electrohydraulic servovalve is a mechatronic component .A mechatronic system is a mixed and multi-domain system, different components or parts of which fall within different domains such as mechanical, electrical, hydraulic and control. The servovalve comprises of first stage electronic part (torque motor) and second stage hydraulic part. The electro-magnet torque motor is used as the driving part in hydraulic servo valve. By using torque motor the information could be transduced, generated and processed more easily than as with pure mechanical/ fluid signals. Torque motor is an electro-mechanical transducer; it converts the input electrical energy into the mechanical output. The versatility of torque motor makes electrohydraulic servovalve as an ideal element for signal amplification and manipulation. For torque motors using permanent magnets, Merritt Watton and Blackburn [7, 8& 9] developed a theory that has been widely distributed and followed by authors of books and research papers. Arafa and Rizk made a special review on torque caused by electromagnetic forces. A nonlinear mathematical model based on physical quantities was developed in [10]. This model includes non-linear relations for the torque motor dynamics. From the experimental data and FEA analysis performed in [11], Fussell et al. state that magnetic flux leakage must be considered in the lumped model for torque predictions. Li Songjing [12] has

conducted the study on 3-Dimentional magnetic field analysis of torque motor with and without magnetic fluid. The torque increases linearly with increase in the current input. The magnetic fluid can increase the effect of the magnetic circuit and improve the characteristics of torque when it is filled in the working clearances of the torque motor. E Urata [13] has developed a theory for mathematical model of torque motor. The magnetic reluctance and flux leakage in the torque motor were taken into account, which was ignored in the Merritt model. The results obtained from the mathematical model matches closely with the experimental results. The author further explains the affect of the torque due to unequal air gap which are induced at the time of production process. Wie Bao [14] has worked on the magnetic fluids. Magnetic fluids can introduce a damping force to a hydraulic servo-valve Torque Motor. According to their analysis and experimental results, magnetic fluids can be used to increase the stability of a torque Motor and a Hydraulic servovalve. In the present work torque motor is modeled in detail for analyzing the magnetic field and output torque. The objectives of the work is to compare the time response of the torque motor,

by comparing the different mathematical expressions proposed by various investigators and also to reveal the dynamic characteristics of torque motor, with and without magnetic fluid.

2. Working Principle of Torque Motor

The torque motor has an armature mounted on a torsion pivot spring and is suspended in the air gaps of a magnetic field (Fig1). The two pole pieces, one polarized north and the other south by the permanent magnets, form the framework around the armature and provide paths for magnetic flux flow. When current flows through the coils, the armature becomes polarized and each end is attracted to one pole piece and repelled by the other (Fig 2). The torque exerted on the armature is restrained by the torsion spring upon which the armature is mounted.

Fig. 1 Neutral Position of torque motor Fig. 1 Neutral Position of torque motor

Fig. 2 Energized Position of torque motor Fig. 2 Energized Position of torque motor

The rotational torque created is directly proportional to the amount of polarization or magnetic charge of the armature - increased armature polarization creates a higher force attraction to the pole pieces. Since the amount of polarization of the armature is proportional to the magnetic flux created by the current through the coils, torque output of the torque motor is proportional to the coil input current. The magnetic flux created by the coils is dependent on two factors: the number of coil wire turns and the strength of current that is applied. In other words, the torque of the motor is dependent on the ampere-turns applied. When armature polarization is reversed by input current polarity, the armature is attracted to the opposite pole pieces and the jet deflects to the opposite receiver. The dynamic response of a torque motor can be analyzed both in time domain and frequency domain. Both domains are used in the present work. The model presented by Merritt is summarized below The voltage equations for each coil circuit are

(1)

(2)

Subtracting equation 1 from 2 results in

(3)
It is assumed that the four air gaps constitute the dominant reluctances in the circuit, i.e. the reluctances of magnetic materials are negligible in comparison. Based on symmetry, the reluctances of diagonally opposite air gaps are equal and therefore given by

Fig. 3 Schematic of magnetic flux paths in Torque motor

(4&5)
The Fundamental force equation is

(4&5)

(6)
Because the torques developed in the two air gaps at each end of the armature are in opposition, the net torque developed will be proportional to the difference of the squares of the fluxes. Hence the total net torque developed on the armature is

(7)
In order to simplify the simulation and analysis of a servo-valve torque motor, torque calculation equation is usually liberalized to be

(8)
The dynamics equation of the armature is given

(9)

3.0 Torque Motor with Magnetic Fluid

As a magnetic fluid shows higher saturation magnetization and larger viscosity when it is exposed to the magnetic field inside the working gaps of the torque motor, forces will be introduced by the magnetic fluid on the armature. There are two methods for magnetic fluids to be filled inside the gaps in accordance with different applications. If larger damping forces due to magnetic fluids are needed, magnetic fluids should be filled as shown in Fig. 3. If only resistances due to magnetic fluids on the armature are needed rather than damping forces, magnetic fluids can only be filled inside the gaps without surrounding the armature. In this application, less amount of magnetic fluids are needed. The cross section of a torque motor with magnetic fluids surrounding the end of armature is shown fig.4. In order to investigate the torque motor dynamics in the presence of the magnetic fluid, the viscosity forces and forces due to magnetization of the magnetic fluid studied in detail are given below.

3.1 Forces due to the viscosity of the magnetic fluids

The cross-section of an armature along the magnetic flux inside the air gaps is surrounded by magnetic fluids is assumed to be uniformly distributed, as shown in Fig. 3, The viscosity of the magnetic fluid exerts forces of the armature in its operation. The force on the armature due to the viscosity of magnetic fluids is shown in Fig. 4.

Fig. 3 Forces on the armature of the torque motor due to magnetic fluids

Fig. 4 Force due to the viscosity of magnetic fluids

3.2 Forces due to the magnetization of magnetic fluids

When magnetic fluids are exposed to the magnetic field inside the working gaps, magnetization of magnetic fluids works as stresses on the armature [9]. The stress on the armature developed by magnetic fluids can be written

(10)
The resistance acting on the armature due to the magnetization of magnetic fluids can be calculated as

(11)

3.3 Torque due to magnetic fluids

The torque developed on the armature due to the magnetization of magnetic fluids can be calculated as

(12)

(13)
The total load torque due to magnetic fluids

(14)
Taking into account expressions for electromagnetic forces in torque motor air gaps, where expressions for magnetic fluxes in air gaps (obtained using the first and the second Kirchhoffs' laws for magnetic circuits) is implemented torque produced on armature can be calculated using (in the case of parallel coil connection):

(15)

Where Permanent Magnet Magneto-Motive force is

(16)

Linearising Eq. 15 about the null position (i = 0 and = 0) one can write

Td = K 1i + K 2
Where

(17)

(18 &19)

4.0 Results and discussion

Fig. 5 Variation of torque with current (Merritt)

Fig. 6 Variation of Jet pipe deflection with current

The torque and the Jet pipe deflection obtained for varied current is shown in Fig. 5&6. The torque increases linearly with increase in current. The obtained torque is a function of torque constant and spring constant of the torque motor. The jet pipe deflection had a linear relationship with the input current. The maximum torque is 1.0 Nm and deflection of 0.02 rad for maximum current of 1.0 mA .The stiffness of the flexural tube has a major impact on the deflection.

Fig. 9 Variation of torque with current

Fig. 10 variation of jet pipe deflection with current

The Fig 7& 8 shows the variation of torque and jet pipe deflection for varied input current. The maximum torque obtained from Arafa proposed model is 0.2 Nm and comparatively very less compared that of the Merritt model. This is due to the fact that the armature fully saturates at relatively high current and the total magnetic flux through it will become constant. The torque will be proportional to the jet pipe deflection in which the stiffness of the flexure tube will have the negative effect from magnetic torque gradient on the armature. The maximum deflection of the jet pipe is 0.05 rad.

Fig.11 Variation of torque with current (E.Urata)

Fig. 12 variation of jet pipe deflection with current

Fig 11 &12 shows the variation of torque and Jet pipe deflection with varied input current for mathematical model Proposed by E.urata. The initial torque is 0.18 N-m for zero current and zero deflection for zero current .The models incorporates the effect of magnetic reluctance and flux leakage through the air gap. The jet pipe deflection is maximum of 0.2 rad for input current of 1.0 mA.

4.1 Time response

The response of the system for a step input according Merritt model with magnetic fluid is shown in Fig 13 &14. It can be seen that the resultant system response is oscillatory with decreasing amplitude. The transient response of the system will die out after a time interval of 0.09 seconds. The peak amplitude was found to be 0.192 and reduced to 0.167 with introduction of magnetic fluid. The peak overshoot was reduced from 97% to 71.2% for the same time of 0.0005 seconds.

Fig. 13 Step response of torque motor (Merritt)

Fig. 14 Step response of torque motor with magnetic fluid

The response of the system for a step input according Urata model and also with magnetic fluid is shown in Fig. 15 &16. By introducing the magnetic fluid the peak amplitude was reduced from 0.109 to 0.935. The overshoot was also reduced from 97.1% to 68.95% at the time of 0.0005 seconds. The rise time was increased from 0.00167 to 0.00183 seconds

Fig. 15 Step response of torque motor (E.Urata)

Fig. 16 Step response of torque motor with magnetic fluid

Fig. 17 Impulse response of torque motor (Merritt) Fig. 18 Impulse response of torque motor with magnetic Fluid The response of the system for a impulse input according Merritt model and also with magnetic fluid is shown in Fig 17 &18. The amplitude was found to be decreased from 572 to 493 at time of 0.0002 seconds this is due to magnetic fluid effect. By introducing the magnetic fluid the settling time was reduced from 0.0067 to 0.0061 seconds

The response of the system for a impulse input according reluctance induced model and also with magnetic fluid is discussed below. The peak amplitude of the response was found to reduce from 342 to 297 at time of 0.002 seconds is shown in fig 19& 20. This is due to introduction of magnetic fluid in the Urata model. The settling time was also improved from 0.0068 to 0.00663 seconds. The magnitude of the vibration is also found to be much effected in the model. The magnitude of vibration due to impulse input was found to be decreased compared to the Merritt model.

Fig. 19 Impulse response of torque motor (E. Urata) fluid

Fig. 20 Impulse response of torque motor with magnetic

4.2 Frequency response

Fig. 21 Dynamic charactertics of torque motor fluid)

Fig. 22 Dynamic charactertics of torque Motor (with magnetic

The dynamic charactertics of the torque motor with magnetic fluid are expressed in Bode plots as shown in Fig (21&22). It is clearly evident from the figure that magnitude of the vibration has been reduced from 14 db at a frequency of 5.96 *103 to -6.83 db at a frequency of 5.89 *103 due to the presence of magnetic fluid in the air gaps. This shows that magnetic fluids are inducing the damping force on the motion of the armature.

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Fig. 23 Dynamic charactertics of torque motor Fig. 24 Dynamic charactertics of torque Motor (with magnetic fluid) The Bode plot for the torque motor for the model proposed by E.Urata is as shown in Fig.23&24. It can be seen from the figure that maximum magnitude of the figure is 12.6dB. The phase margin is equal to 200 and gain cross over frequency is equal to 6.48103 rad/s. By introduction of magnetic fluid in the torque motor the -6.83 at 5.89 103 rad/s.

5. Conclusions
In the present work an attempt has been made to study the dynamics of the torque motor by considering the mathematical models proposed by different authors. The dynamics of torque motor used in jet pipe electrohydraulic servovalve is studied by comparing the time and frequency responses. The torque generated and deflections were plotted for varied current input. The torque varies from 0.2 Nm to 1.0 Nm for the current of 1.0mA. The maximum jet pipe deflection varies from 0.05 to 0.2 rad for the current of 1.0mA. The dynamic characteristics of a hydraulic servo-valve can be improved due to the application of magnetic fluids. The resonance frequency of a hydraulic torque motor was found to be 900Hz and the magnitude of the vibration was found to be14 db. The Magnetic fluids can be used to increase the stability of a torque motor and a hydraulic servo-valve. The magnitude of vibration was 6.83 db. The operating band width was also improved. But, at the same time, the amplitude of the rotation angle of the torque motor may also be reduced slightly. Therefore care must be taken when different types of magnetic fluids are selected for the application.

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Nomenclature
RP N Resistance of each coil, 100 ohms Number of turns in each coil 4400 Ms Saturation magnetization of magnetic uid 0.04 (T) Viscosity of magnetic uid 3.0 (Pa s)

mf
M1 K1 K2 r xp0 Ap kr o JL B Kt Km Ka

d dt
rp Ebb Zp R1 R2 g x Ag o F A

Total magnetic flux through the armature, lines Internal resistance (plate resistance) of

permanent magnet magneto motive force 586 A Torque constant of the torque motor 1.21 (N m/A) torque motor electromagnetic spring constant 2.42(N m/rad) Distance from armature pivot to the centre of permanent magnet pole face, 14.510-3 m Length of each air gap at null, 0.4510-3 m torque motor gap area 910-6 m2 Magnetic reluctance constant 0.465 Permeability of free space 4 x10-7 H/m Jet pipe length 0.0277m Flux density in the air 0.66 (Wb/m2) Torque constant of the torque motor 1.0(N m/A) Mechanical torsion spring constant of spring pipe 1.615 (Nm/rad) Magnetic spring constant 1.536 (N m/rad)

amplifier in each coil circuit, Constant voltage required for quiescent current, Impedance in common line of coils, Reluctance of gaps 1 and 3, amp-turn/line Reluctance of gaps 2 and 4, amp turn/line Length of air gap at neutral, 1 mm Displacement of the armature tip from the neutral position, m Pole face area at the gaps, 3.9 * 3 mm2 Permeability of free space (air) Attractive force between magnetized parallel surfaces separated by an air gap, Magnetic flux in the air gap Area normal to flux path, m2

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[2] Cho SK, Lee H-H. A fuzzy-logic antiswing controller for three-dimensional overhead cranes. ISA Trans 2002; 41(2):23543 [3] Davliakos I, Papadopoulos E. Model-based control of a 6-dof electrohydraulic StewartGough platform. Mech Theory 2008;43(11):1385400 [4] Zhao, C., Gao, K., Liu, X.,Wen, B.,. Control of electrohydraulic servo system for a material test system using fuzzy neural network. In: Proceedings of the world congress on intelligent control and automation (WCICA). Proceedings of the 7th world congress on intelligent control and automation, 2008;. 93519355. [5] Barai RK, Nonami K. Optimal two-degree-of-freedom fuzzy control for locomotion control of a hydraulically actuated hexapod robot. Inform Sci 2007; 177(8):1892915. [6] Maskrey, R. H. and Thayer, W. J. A brief history of electrohydraulic servomechanisms. Moog Tech.Bull., 1978, 141, 110116. [7] Merritt, H. Hydraulic Control Systems, John Wiley & Sons, New York (1967.

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[8] Watton, J . Fluid Power Systems: Modeling, Simulation, Analog and Microcomputer Control, Prentice Hall International Ltd. UK, 1989. [9] Lee, S., J.F. Blackburn, Contribution to Hydraulic Control-1 Steady-State Axial Forces on Control-valve Pistons. Transactions of the ASME, 1952, pp 1005-1011 Cambridge, and Mass [10] Arafa, H. A. and Rizk, M. Identification and Modelling of Some Electrohydraulic Servo-Valve NonLinearities. Proceedings of the Institution of Mechanical Engineers, Part C: Mechanical Engi-neering Science (1987), vol. 201, no. 2, pp. 137-144. [11] Fussell, B., Darwin, J., Prina S. Servovalve Torque Conference/Electrical Manufacturing & Coil Winding Expo, 1999 Motor Analysis, Electrical Insulation

[12] Li Songjing, Jiang Dan, Xu Benzhou, Sheng Xiaowei. 3D Magnetic Field Analysis of Hydraulic Servovalve Torque Motor with Magnetic Fluid. IEEE Electrical Machines and Systems; Vol 3; pp 2447 2450 [13] Urata. On the Torque Generated in a Servovalve Torque Motor using Permanent Magnet. IMechE 2007, Vol 221, pp 519-526. [14] Wei Bao Characteristics Analysis of Hydraulic Servo-Valve Torque Motor Using Magnetic Fluid ASME Conference DETC2005-84704 pp. 151-158

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