Closed-Loop Hydraulics

Workbook TP 511

Festo Didactic 094469 en

Authorised applications and liability The Learning System for Automation and Communication has been developed and prepared exclusively for training in the field of automation and communication. The training organisation and / or trainee shall ensure that the safety precautions described in the accompanying Technical documentation are fully observed. Festo Didactic hereby excludes any liability for injury to trainees, to the training organisation and / or to third parties occurring as a result of the use or application of the station outside of a pure training situation, unless caused by premeditation or gross negligence on the part of Festo Didactic. Order No.: Description: Designation: Edition: Layout: Graphics: Authors: 094469 ARBB.REGELH.GS D:S511-C-SIBU-GB 08/2000 17.08.2000, OCKER Ingenieurbro OCKER Ingenieurbro A.Zimmermann, D.Scholz

Copyright by Festo Didactic GmbH & Co., D-73770 Denkendorf 2000 The copying, distribution and utilisation of this document as well as the communication of its contents to others without expressed authorisation is prohibited. Offenders will be held liable for the payment of damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design registrations. Parts of this training documentation may be duplicated, solely for training purposes, by persons authorised in this sense.

TP511 Festo Didactic

Preface
Festo Didactics Learning System for Automation and Communications is designed to meet a number of different training and vocational requirements. The Training Packages are structured accordingly:

T Basic Packages provide fundamental knowledge which is not limited

to a specific technology.

T Technology Packages deal with the important areas of open-loop and

closed-loop control technology.

T Function Packages explain the basic functions of automation systems.

T Application Packages provide basic and further training closely oriented to everyday industrial practice. Technology Packages deal with the technologies of pneumatics, electropneumatics, programmable logic controllers, hydraulics, electrohydraulics, proportional hydraulics closed loop pneumatics and hydraulics.
Mounting frame

Fig. 1: Example of Hydraulics 2000: Mobile laboratory trolley

U = 230V~ Profile plate p = 6 MPa

Storage tray

TP511 Festo Didactic

The modular structure of the Learning System permits applications to be assembled which go beyond the scope of the individual packages. It is possible, for example, to use PLCs to control pneumatic, hydraulic and electrical actuators. All training packages have an identical structure:

T T T T

Hardware Courseware Software Courses

The hardware consists of industrial components and installations, adapted for didactic purposes. The courseware is matched methodologically and didactically to the training hardware. The courseware comprises:

T Textbooks (with exercises and examples) T Workbooks (with practical exercises, explanatory notes, solutions and
data sheets)

T OHP transparencies, electronic transparencies for PCs and videos

(to bring teaching to life) Teaching and learning media are available in several languages. They have been designed for use in classroom teaching but can also be used for self-study purposes. In the software field, CAD programs, computer-based training programs and programming software for programmable logic controllers are available. Festo Didactics range of products for basic and further training is completed by a comprehensive selection of courses matched to the contents of the technology packages.

TP511 Festo Didactic

Latest information about the technology package Closed loop hydraulics TP511. New in Hydraulic 2000:

T Industrial components on the profile plate. T Exercises with exercise sheets and solutions, leading questions. T Fostering of key qualifications:
Technical competence, personal competence and social competence form professional competence.

T Training of team skills, willingness to co-operate, willingness to learn,

independence and organisational skills. Aim Professional competence

Content Part A Part B Part C Part D Course Fundamentals Solutions Appendix Exercises Reference to the text book Function diagrams, circuits, descriptions of solutions and equipment lists Storage tray, mounting technology and datasheets

TP511 Festo Didactic

Table of contents
Technology package TP511 Closed loop hydraulics Safety recommendations Notes on procedure Standard method of representation used in circuit diagrams Technical notes Component/exercise table Equipment set TP511 12 13 13 14 15 16 18

Section A Course
1. Pressure control loop Exercise 1: Exercise 2: Pipe-bending machine Characteristics of a pressure sensor Forming plastic products Pressure characteristic curve of a dynamic directional control valve Cold extrusion Regulated pressure control Thread rolling machine Characteristics of a PID controller card Stamping machine Transition function of a P controller Clamping device Control quality of a pressure control loop with P controller Injection moulding machine Transition functions of I and PI controllers Pressing-in of bearings Transition functions of D, PD and PID controllers Welding tongs of a robot Empirical setting of parameters of a PID controller A-3

A-13 A-25 A-33 A-39

Exercise 3: Exercise 4: Exercise 5: Exercise 6:

A-49 A-61 A-75 A-89

Exercise 7: Exercise 8: Exercise 9:

Exercise 10: Pressure roller of a rolling machine Setting parameters using the Ziegler-Nichols method A-97

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Exercise 11: Edge-folding press with feeding device Modified controlled system with disturbance variables 2. Position control loop Exercise 12: Table-feed of a milling machine Characteristic curve of a displacement sensor Exercise 13: X/Y-axis table of a drilling machine Flow characteristic curves of a dynamic directional control valve

A-105

A-115

A-125

Exercise 14: Feed unit of an assembly station Linear unit as controlled system for position control A-141 Exercise 15: Automobile simulator Assembly and commissioning of a position control loop Exercise 16: Contour milling Lag error in position control loop Exercise 17: Machining centre Position control with modified controlled system Exercise 18: Drilling of bearing surfaces Commissioning of a position control loop with disturbance variables Exercise 19: Feed on a shaping machine Characteristics and transition functions of a status controller Exercise 20: Paper feed of a printing machine Parameterisation of a status controller Exercise 21: Horizontal grinding machine Position control loop with disturbance variables and active load

A-159 A-173 A-185

A-191

A-205 A-215

A-227

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Section B Fundamentals
Chapter 1 Fundamentals
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 Signals Block diagram Signal flow diagram Test signals Open-loop and closed-loop control Terminology of closed-loop technology Stability and instability Steady-state and dynamic behaviour Response to setpoint changes and interference Fixed-value, follower and timing control systems Differentiation of a signal Integration of a signal

B-3
B-4 B-8 B-10 B-12 B-14 B-16 B-19 B-20 B-23 B-25 B-27 B-31

Chapter 2 Hydraulic controlled systems

2.1 2.2 2.3 2.4 2.5 2.6 2.7 Controlled systems with and without compensation Short-delay hydraulic controlled systems First-order hydraulic controlled systems Second-order hydraulic controlled systems Third-order hydraulic controlled systems Classification of controlled systems according to the step response behaviour Operating point and system gain

B-35
B-37 B-39 B-40 B-41 B-43 B-45 B-46

Chapter 3 Controller structures

3.1 3.2 3.3 3.4 3.5 3.6 Non-dynamic controllers Block diagrams for non-dynamic controllers P controller I controller D controller element PI, PD and PID controller

B-49
B-51 B-53 B-55 B-57 B-59 B-62

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3.7 3.8 3.9 3.10

Block diagrams for dynamic standard controllers Status controllers Selection of controller structure Response to interference and control factor

B-68 B-72 B-75 B-77

Chapter 4 Technical implementation of controllers

4.1 4.2 4.3 4.4 Structure of closed control loops Hydraulic and electrical controllers Analogue and digital controllers Selection criteria for controllers

B-83
B-84 B-90 B-92 B-95

Chapter 5 Directional control valves

5.1 5.2 5.3 5.4 5.5 5.6 5.7 Valve designs Purpose and modules of a directional control valve Designations and symbols for dynamic directional control valves Mode of operation of a dynamic 4/3-way valve Steady-state characteristic curves of dynamic directional control valves Dynamic behaviour of dynamic directional control valves Selection criteria for directional control valves

B-97
B-98 B-99 B-102 B-105 B-111 B-116 B-120

Chapter 6 Pressure regulators

6.1 6.2 6.3 6.4 6.5 Function of a pressure regulator Pressure regulator designs Mode of operation of a pressure regulator Pressure control with a directional control valve Selection criteria for pressure regulating valves

B-121
B-122 B-123 B-124 B-128 B-129

Chapter 7 Measuring systems

7.1 7.2 7.3 Function of a measuring system Measuring system designs and interfaces Selection criteria for measuring systems

B-131
B-132 B-133 B-136

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Chapter 8 Assembly, commissioning and fault finding

8.1 8.2 8.3 8.4 8.5 8.6 Closed control loops in automation Planning Assembly Commissioning Controller setting Fault finding

B-137
B-138 B-141 B-144 B-146 B-149 B-155

Section C Solutions
Exercise 1: Exercise 2: Exercise 3: Exercise 4: Exercise 5: Exercise 6: Exercise 7: Exercise 8: Exercise 9: Pipe-bending machine Forming of plastic products Cold extrusion Thread rolling machine Stamping machine Clamping device Injection moulding machine Pressing-in of bearings Welding tongs of a robot C-3 C-5 C11 C-13 C-15 C-19 C-23 C-25 C-29 C-31 C-35 C-39 C-41 C-49 C-55 C-61 C-65 C-67 C-73 C-77 C-81

Exercise 10: Pressure roller of a rolling machine Exercise 11: Edge-folding press with feeding device Exercise 12: Table-feed of a drilling machine Exercise 13: X/Y-axis table of a drilling machine Exercise 14: Feed unit of an assembly station Exercise 15: Automobile simulator Exercise 16: Contour milling Exercise 17: Machining centre Exercise 18: Drilling of bearing surfaces Exercise 19: Feed on a shaping machine Exercise 20: Paper feed of a printing machine Exercise 21: Horizontal grinding machine

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Section D Appendix
Operating notes Storage tray Mounting technology Sub-base Coupling system Guidelines and standards List of literature Index Data sheets 2 3 4 6 7 9 10 11 19

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Technology package TP511 Closed loop hydraulics

The technology package TP511 Closed loop hydraulics forms part of Festo Didactics Learning System for Automation and Communications. The training aims of TP511 are concerned with learning the fundamentals of analogue control technology. With electrical control and closed loop elements, hydraulic actuators are activated. A basic knowledge of electrohydraulics and electrical measuring technology is therefore recommended to work with this technology package. The exercises in TP511 cover the following main topics:

T Pressure control with PID controller (exercise 1 11) T Position control with PID controller (exercise 12 18) T Position control with status controller (exercise 19 21)
The fundamentals dealt with in TP511 concern:

T A classification of hydraulic controlled systems T A description of different controller structures T Notes regarding the technical implementation of controllers, valves
and sensors

T Tips on the assembly and commissioning of hydraulic closed control

loops The components of the equipment set to be used for the individual exercises are listed in the component/exercise table overleaf.

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Safety recommendations
The following safety advice should be observed in the interest of your own safety:

T Caution! Cylinders may advance as soon as the hydraulic power pack

is switched on!

T Do not exceed the permitted working pressure (see data sheets). T Use only extra-low voltages of up to 24 V. T Observe general safety regulations (DIN58126 and VDE100).

Notes on procedure
Construction The following steps are to be observed when constructing a control circuit. 1. The hydraulic power pack and the electrical power supply unit must be switched off during the construction of the circuit. 2. All components must be securely attached to the slotted profile plate i.e. safely latched and securely mounted. 3. Please check that all return lines are connected and all hoses securely connected. 4. Make sure that all cable connections have been established and that all plugs are securely plugged in. 5. First, switch on the electrical power supply unit and then the hydraulic power pack. 6. Make sure that the hydraulic components are pressure relieved prior to dismantling the circuit, since: Couplings must be connected unpressurised! 7. First, switch off the hydraulic power pack and then the electrical power supply unit.

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Standard method of representation used in circuit diagrams

The hydraulic circuit diagrams are based on the following rules:

T T T T

Clear representation avoiding crossovers as far as possible Symbols conforming to DIN/ISO 1219 Part 1 Circuit diagrams with several loads are divided into control chains Identification of components in accordance with DIN/ISO 1219 Part 2: Each control chain is assigned an ordinal number 1xx, 2xx, etc. The hydraulic power pack is control chain 0xx. Identification of components by letters: A Power component B Electrical sensors P Pump S Signal generator V Valve Z Other component The complete code for a component consists of a digit for the control chain, a letter for the component, a digit for the consecutive numbering of components in accordance with the direction of flow in the control chain. Example: 1V2 = Second valve in control chain 1.

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Technical notes
The following notes are to be observed in order to ensure trouble-free operation.

T An adjustable pressure relief valve has been integrated in the hydraulic power pack Pt. No. 152962. For reasons of safety, the system pressure has been limited to approx. 6 MPa (60 bar).

T The maximum permissible pressure for all hydraulic components is

12 MPa (120 bar). The working pressure is to be at a maximum of 6 MPa (60 bar).

T In the case of double-acting cylinders, an increase in pressure may

occur according to the area ratio as a result of pressure transference. With an area ratio of 1:1.7 and an operating pressure of 6 MPa (60 bar) this may be in excess of 10 MPa (100 bar)!
Fig. 2: Pressure transference

T If the connections are released under pressure, pressure is locked

into the valve or device via the non-return valve in the coupling (see Fig. 3). This pressure can be reduced by means of pressure relieving device Pt. No. 152971. Exception: This is not possible in the case of hoses and non-return valves.

T All valves, equipment and hoses have self-sealing couplings. These

prevent inadvertent oil spillage. For the sake of simplicity, these couplings have not been represented in the circuit diagrams.
Fig. 3: Symbolic representation of sealing couplings
Flow restrictor Hose Shut-off valve

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Component/exercise table
Exercises Description
Power pack (2 l) Power pack (2 x 4 l) Pressure filter Braking cylinder Linear unit Loading weight (5 kg) Pressure relief valve Flow control valve Shut-off valve 4/3-way regulating valve Hydraulic motor Flow meter Pressure gauge Pressure sensor Hose, 600 mm Hose, 1000mm Hose, 3000mm T-distributor 1 1 1 1 2 1 1 2 2 1 1 2 1 2 1 2 1 1 1 1 1 1 6 2 1 4 1 1 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 3 2 2 2 2 2 2 2 2 2 1 1 6 2 2 2 4 1 1 7 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1

1
1

2
1

3
1

6
1

9
1

10 11 12 13 14 15 16 17 18 19 20 21
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

PID controller Status controller Universal display

1 1 1 1

Digital multimeter Oscilloscope Function generator Cable, BNC/4 mm Cable, BNC/BNC T-piece, BNC Cable set, universal Power supply unit

1 1

1 1

1 1 1 2 1 1 1 1

1 1 1 2 1 1 1 1

1 1 1 2 1 1 1 1

1 1 1 2 1 1 1 1

1 1 1 2 1 1 1 1

1 1 1 2 1 1 1 1

1 1

1 1 1 2 1 1

1 1 1 2 1 1 1 1

1 1 1 2 1 1 1 1

1 1 1 2 1 1 1 1

1 1 1 2 1 1 1 1

1 1 1 2 1 1 1 1

1 1 1 2 1 1 1 1

1 1

1 2 1 1

1 1 1

1 2 1 1

1 1

1 2

1 3

1 1

1 1

1 1

1 1

1 1

1 1

1 1

1 1

1 1

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Workbook concept
The workbook is divided into the following sections: Section A Course Section B Fundamentals Section C Solutions Section D Appendix In Section A, Course, progressive exercises are used to explain the assembly and commissioning of analogue closed control loops. The necessary technical knowledge required to complete an exercise is provided at the start of each exercise. Non-essential details are avoided. More detailed information is given in Section B. Section C, Solutions gives the results of the exercises with a brief explanation. Section B, Fundamentals contains general technical knowledge, which complements the training contents of the exercises in Section A. Theoretical relationships are illustrated and the necessary specialist terminology is explained in a clearly understandable way by means of examples. Section D, Appendix is intended as a means of reference. It contains data sheets, a list of literature and an index. The layout of the book has been structured to allow the use of its contents both for practical training, e.g. in classroom courses, and for selfstudy purposes.

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Equipment set TP511

Equipment set TP511 Closed loop hydraulics, complete, Order No. 184471 Description
Components for hydraulics general Components for pressure control Components for position control

Order No.
091070 184472 184473

Quantity
1 1 1

Components Hydraulics general Order No.091070

Description
Pressure filter Pressure relief valve Flow control valve Hydraulic motor Pressure gauge T-distributor

Order No.
152969 152848 152842 152858 152841 152847

Quantity
1 1 1 1 1 4

Components for pressure control, Order No. 184472

Description
4/3-way regulating valve PID controller

Order No.
167088 162254

Quantity
1 1

Components for position control, Order No. 184473

Description
Linear unit Loading weight (5kg) Status controller

Order No.
167089 034065 162253

Quantity
1 2 1

Additional components for exercise 21

Description
Braking cylinder

Order No.
152295

Quantity
1

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Description
Power pack (1 x 4 l) Power pack (2 x 4 l) Workbook, DE Workbook, GB Digital multimeter Pressure sensor (included in measuring set) Flow meter (included in measuring set) Function generator Cable, BNC/4mm Cable, BNC/BNC Cable set with safety plugs Measuring set Power supply unit (for mounting frame) Table top power supply unit Oscilloscope Profile plate, 550 x 700 mm Hose, 600 mm Hose, 1000 mm Hose, 3000 mm T-piece, BNC Universal display (included in measuring set)

Order No.
152962 186085 094460 094469 035681 184133 183736 152918 152919 158357 167091 177468 159396 162417 152917 159409 152960 152970 158352 159298 183737

Quantity
1 1 1 1 1 2 1 1 3 1 1 1 1 1 1 1 7 4 2 1 1

List of additional devices

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Symbols for the equipment set TP511

Designation
Double-acting cylinder

Explanation
single-ended piston rod

Symbol

Double-acting cylinder

double-ended piston rod

Pressure gauge

Flow control valve

adjustable

Pressure relief valve

adjustable

Pressure regulating valve

adjustable

Shut-off valve

Reservoir

Connection at both sides

Energy source

hydraulic

Manual operation

general

Plugged port

2/2-way valve

Normally closed

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Designation
4/3- way valve

Explanation
mid position closed

Symbol

Symbols for the equipment set TP511

4/3- way dynamic valve

mid position closed

Converter

general

Adjuster

general

Sensor

hydraulic / electrical

Pressure gauge

general

Flow sensor

electrical

Limiter

electrical

Pressure sensor

electrical

Flow meter

general

Amplifier

general

Operational amplifier

general

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Symbols for the equipment set TP511

Designation
Regulator general

Explanation

Symbol

Electrical actuation

solenoid with one winding

Electrical actuation

solenoid with two opposed winding, infinitely adjustable

Manual actuation

by means of spring

Pilot actuated

indirect by application of pressure

Switch

detent function

Working line

line for energy transmission

Line connection

fixed connection

Link

collecting or summation point

Electrical line

line for electrical power transmission

Linear scale

Mass

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Designation
Transmission element

Explanation
proportional time response

Symbol

Symbols for the equipment set TP511

Transmission element

PT1 time response

Transmission element

integral time response

Transmission element

differential time response

Transmission element

two-step action without hysteresis

Transmission element

two-step action and hysteresis, different hysteresis

Transmission element

three-step action

Transmission element

three-step action with two different hysteresis

Transmission element

PD time response

Transmission element

PI time response

Transmission element

PID time response

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Symbols for the equipment set TP511

Designation
Voltage generator

Explanation
D.C. voltage

Symbol

Voltage generator

square-wave voltage

Voltage generator

sine-wave voltage

Voltage generator

triangular-wave voltage

Oscilloscope

Display

indicator light

Voltmeter

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A-1

Part A Course
1. Pressure control loop Exercise 1: Exercise 2: Pipe-bending machine Characteristics of a pressure sensor Forming plastic products Pressure characteristic curve of a dynamic directional control valve Cold extrusion Regulated pressure control Thread rolling machine Characteristics of a PID controller card Stamping machine Transition function of a P controller Clamping device Control quality of a pressure control loop using a P controller Injection moulding machine Transition functions of I and PI controllers Pressing-in of bearings Transition functions of D, PD and PID controllers Pressing-in of bearings Transition functions of D, PD and PID controllers A-3

A-13 A-25 A-33 A-39

Exercise 3: Exercise 4: Exercise 5: Exercise 6:

A-49 A-61 A-75 A-89

Exercise 7: Exercise 8: Exercise 9:

Exercise 10: Pressure roller of a rolling machine Setting parameters using the Ziegler-Nichols method Exercise 11: Edge-folding press with feeding device Modified controlled system with disturbance variables

A-97

A-105

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A-2

2. Position control loop Exercise 12: Table-feed of a milling machine Characteristic curve of a displacement sensor Exercise 13: X/Y-axis table of a drilling machine Flow characteristic curves of a dynamic directional control valve A-115

A-125

Exercise 14: Feed unit of an assembly station Linear unit as controlled system for position control A-141 Exercise 15: Automobile simulator Assembly and commissioning of a position control loop Exercise 16: Contour milling Lag error in position control loop Exercise 17: Machining centre Position control with modified controlled system Exercise 18: Drilling of bearing surfaces Commissioning of a position control loop with disturbance variables Exercise 19: Feed of a shaping machine Characteristics and transition functions of a status controller Exercise 20: Paper feed of a printing machine Parameterisation of a status controller Exercise 21: Horizontal grinding machine Position control loop with disturbance variables and active load

A-159 A-173 A-185

A-191

A-205 A-215

A-227

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A-3
Exercise 1

Closed-loop hydraulics Pipe-bending machine

Subject Title

T To learn about the mode of operation of a pressure sensor T To be able to record and evaluate a characteristic curve T To be able to understand the significance of a characteristic curve
Sensors A sensor acquires a physical variable, such as pressure, temperature, flow or speed, and converts this into an electrical or mechanical signal. The form of output signal can be binary, digital or analogue.

Training aim

Technical knowledge

T The binary output signal describes two switching statuses, e.g. ON

and OFF or 0V and 10V.

T The digital output signal corresponds to a number created by the T The analogue output signal is produced in a continuous curve. Theoretically, it can assume any interim value. For instance, the pointer deflection of a pressure gauge or a voltmeter. Sensors are also occasionally referred to as signal converters or, in conjunction with closed-control loops as measuring systems and measuring transducers.

addition of several pulses of identical size, e.g. increments of a scale or bits.

Analogue pressure sensor The sensor used in this case converts the measured variable pressure into an analogue, electrical signal. The characteristics of the sensor are:
Supply voltage
13V to 30V

Input variable
0bar to 100bar

Output variable
0V to 10V or 4mA to 20mA

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A-4
Exercise 1

Fig. A1.1: Circuit and block diagram of analogue pressure sensor

Characteristic curve The relationship between the input and output variable of a sensor is described by means of a characteristic curve. The following characteristic data can be read (see also fig. A1.2):

T Input range or measuring range between the smallest and largest

input value which can be recorded.

T Output range between the smallest and largest possible output signal.

T In the linear range the characteristic proceeds in the form of a

straight line with a constant gradient producing a unique correspondence between the change of the input signal and the change of the output signal. Sensors are particularly suitable for measuring input variables in this range.

T Transfer coefficient (frequently referred to as gain) is proportional to

the gradient of the characteristic curve in the linear range. It is calculated accordingly from the change of the output signal in relation to the change of the input signal: Transfer coeffizient K = Output signal Input signal

T Hysteresis describes the difference between characteristic curves

recorded with rising and falling measured variables, which should be as small as possible. The maximum difference as a percentage in relation to the input range represents the operative characteristics: max. difference Hysteresis H = Input range 100%

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Exercise 1

Fig. A1.2: Characteristic curve of a sensor

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A-6
Exercise 1

Problem description

A pipe-bending machine is used to bend pipes of varying diameters, wall thickness and material of different dimensions. The required bending force is produced by a hydraulic cylinder. The pressure in the hydraulic cylinder is maintained constant by means of a pressure control loop. The measuring system in the pressure control loop is a pressure sensor. The closed control loop is to be reset in the course of maintenance work. First of all, the characteristic values of the measuring system are to be checked. To do so, the characteristic curve of the pressure sensor must be recorded.

Positional sketch

Exercise

Characteristic curve of the pressure sensor 1. Designing and constructing the measuring circuit 2. Recording the characteristic curve of the pressure sensor 3. Deriving the characteristics of the pressure sensor from the measuring results

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A-7
Exercise 1

1. Measuring circuit Frequently, a characteristic curve has to be recorded on the spot using the devices available. Hence the input variable of the pressure sensor (= pressure in bar) is measured by means of a pressure gauge and the output variable (= voltage in V) by means of a multimeter. The accuracy of a measuring circuit of this type is generally adequate to check the sensor function. A pressure relief valve is built into the hydraulic circuit to set the different pressures. These are displayed by means of a pressure gauge. The electrical circuit consists of the voltage supply for the pressure sensor and a voltage measuring device for the output signal of the pressure sensor. 2. Characteristic curve First, the pressure relief valve is opened completely. The entire oil flow returns de-pressurised from the pump to the tank. The pressure sensor display shows 0V. Pressure is then gradually increased by closing the pressure relief valve. The pressure levels and the pressure sensor readout are entered in a values table. Once the maximum pump pressure has been reached, this series of measurements is repeated with falling pressure.

Execution

Note the following when recording the characteristic curve

T accurate setting of pressure values T rising or falling direction of measurement.

The characteristic curve of the pressure sensor is represented by plotting

T the input variable (pressure p in bar) on the x-axis and T the output variable (voltage V in Volts) on the y-axis.

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A-8
Exercise 1

3. Characteristics The most important characteristics of a pressure sensor are:

T T T T

Measuring range Connection values Transfer coefficient Hysteresis.

These values can be taken from the data sheet. It is, however, often necessary to carry out a check by means of a series of measurements. It is not possible to establish the complete measuring range of the pressure sensor with the items of equipment available. Since the pump supplies less than 100bar, it is not possible to traverse the entire input pressure range. It is nevertheless possible to calculate the transfer coefficient in the linear range, which is the most important one for setting a closed control loop. There is no point in calculating hysteresis, since any possible differences are more likely due to the inaccuracy of the pressure gauge rather than the features of the pressure sensor.

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Exercise 1

WORKSHEET

Characteristic curve of a pressure sensor 1. Measuring circuit

T Familiarise yourself with the required items of equipment.

What characteristics describe the pressure sensor? Input range: _____________________________________________ Output range: ___________________________________________ Supply voltage: __________________________________________ Designate the characteristics of the pressure gauge: Measuring rang: _________________________________________ Measuring accuracy: ______________________________________

T Construct the measuring circuit, starting with the hydraulic and then
the electrical part.

Circuit diagram, hydraulic

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A-10
Exercise 1

Circuit diagram, electrical

2. Characteristic curve

T Open the pressure relief valve completely. T Switch on the voltage first. T Then switch on the hydraulic pump.
What output signal does the pressure sensor supply?

T Slowly close the pressure relief valve. Traverse the measuring range
by way of a test.

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A-11
Exercise 1

WORKSHEET

T Record the characteristic curve of the pressure sensor.

Observe the direction of measurement: rising or falling input variable!

Measured values
0 10 20 30 40 50 60 70 80

Measured variable and unit

Pressure p in bar Voltage V in volts Voltage V in volts

Direction of measurement

Value table

rising falling

T Enter the measured values in the diagram. Identify the axes:

x-axis for input variable y-axis for output variable
Diagram

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A-12
Exercise 1

3. Characteristics

T Establish the following characteristics from the diagram:

Input range: Output range: Measuring rang: Linear range: Transfer coefficient: Hysteresis:

T How do you evaluate the use of this pressure sensor within the
framework of the circuits given with this equipment set? State your reasons for this:

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