1. Master Thesis Defense
“Hardware-in-the-loop simulation of a servo cylinder test
rig operating in a closed loop position control system
under the effect of a servo loading cylinder”
Submitted by
Khaled Hossam Emam
Under Supervision of
Dr. Eng. Taher M. Salah El din
Master Thesis Defense
Faculty of Engineering and Material Science
Mechatronics Department
The German University in Cairo

2. Master Thesis Defense
Khaled H. Emam Slide 2/58
Outline
 Introduction
 Mechanical Design
 Hydraulic Design
 Controller Design
 Data Acquisition
 Results
 Conclusion

3. Master Thesis Defense
Khaled H. Emam Slide 3/58
 Background and Motivation
 Hydraulic drives are widely used in industry where high forces and heavy
loading conditions should be manipulated.
 In order to reach high dynamic response and high power to weight ratio, servo
control techniques were applied to the hydraulic systems.
 Due to the fact that electrohydraulic systems are complex non-linear system, a
lot of research was dedicated to the are of control and response analysis.
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion

4. Master Thesis Defense
Khaled H. Emam Slide 4/58
 Thesis Objective
 Development and design of a test rig for electrohydraulic components and
systems to be used for research applications and practical courses for students.
 Scope of the Thesis
 Implementing a Hardware In the Loop (HIL) simulator for position control of
a servo cylinder under the effect of loading servo cylinder.
 This study is mainly based on “Salah el-din, T. (2010). "Enhancement of
performance of an electrohydraulic servo system for mold oscillation control
in continuous casting machines". Ph.D thesis. Cairo University, Faculty of
Engineering, Egypt.”
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion

5. Master Thesis Defense
Khaled H. Emam Slide 5/58
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion

6. Master Thesis Defense
Khaled H. Emam Slide 6/58
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
Photograph of Servo Cylinder Test Rig Institute of
Fluid Power (TU Dresden)

7. Master Thesis Defense
Khaled H. Emam Slide 7/58
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
Photograph of Servo Cylinder Test Rig at
EZDK Steel Plant

8. Master Thesis Defense
Khaled H. Emam Slide 8/58
 Working Plan
 Study the mechanical and hydraulic components for test rig assembly.
 Closed loop Control analysis for both position controlled servo cylinder and
force controlled loading servo cylinder, i.e. implementing a system model
using Matlab/Simulink.
 Considering the electrical and electronic interface between the hardware and
software planes.
 Calculation of controller parameters using classic control techniques and
manual tuning on the test rig at EZDK steel plant.
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion

9. Master Thesis Defense
Khaled H. Emam Slide 9/58
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion

10. Master Thesis Defense
Khaled H. Emam Slide 10/58
1 Operating Cylinder
2 Base Block
3 Cross Block- operating side
4 Operating Rod
5 Tension Rod
6 Oscillating Block
7 Load Cell Adaptor
8 Load Cell
9 Load Cylinder Rod
10 Loading Cylinder
11 Cross Block- loading side
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion

11. Master Thesis Defense
Khaled H. Emam Slide 11/58
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
Parameter Loading Cylinder
Piston diameter[mm] 100
Piston rod diameter [ mm] 60
Stroke [mm] 100
Piston cross section area [m2] 0.005
Piston chamber volume at piston mid-stroke [m3] 2.5x10-4
Piston mass [kg] 18.5
Maximum operating pressure [MPa] 12
Coefficient of viscous friction [Ns/m] 4255
Parameters of Loading Cylinder

12. Master Thesis Defense
Khaled H. Emam Slide 12/58
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
Parameters of Operating Cylinder
Parameter Operating Cylinder
Piston diameter[mm] 160
Piston rod diameter [ mm] 100
Stroke [mm] 100
Piston cross section area [m2] 0.0122
Piston chamber volume at piston mid-stroke [m3] 6x10-4
Piston mass [kg] 58
Maximum operating pressure [MPa] 7
Coefficient of viscous friction [Ns/m] 12000

13. Master Thesis Defense
Khaled H. Emam Slide 13/58
Three Stage Servo Valve Bandwidth of the three stage servo valve
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
Operating Servo System – Servo Valve

14. Master Thesis Defense
Khaled H. Emam Slide 14/58
Two Stage Servo Valve Bandwidth of the two stage servo valve
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
Loading Servo System – Servo Valve

15. Master Thesis Defense
Khaled H. Emam Slide 15/58
Introduction
Mechanical
Design
Hydraulic
Design
Controller Design Data Acquisition Results Conclusion
Torque Motor
Flapper Valve
Control Spool

16. Master Thesis Defense
Khaled H. Emam Slide 16/58
Introduction
Mechanical
Design
Hydraulic
Design
Controller Design Data Acquisition Results Conclusion
Detailed System Model

17. Master Thesis Defense
Khaled H. Emam Slide 17/58
Introduction
Mechanical
Design
Hydraulic
Design
Controller Design Data Acquisition Results Conclusion
Detailed System Model

18. Master Thesis Defense
Khaled H. Emam Slide 18/58
Introduction
Mechanical
Design
Hydraulic
Design
Controller Design Data Acquisition Results Conclusion
Detailed System Model
0 0.005 0.01 0.015 0.02 0.025 0.03
-0.5
0
0.5
1
1.5
2
2.5
3
x 10
-4
time (sec)
SpoolDisplacement(mm)
linear valve model
detailed valve model

19. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller Design Data Acquisition Results Conclusion
y = Main spool displacement
ζ 𝑠 = damping ratio of the spool,
𝜔0𝑣 = Natural frequency of the valve
𝐾𝑜𝑣 =
Displacement proportionality
coefficient between the control
current and valve spool
𝐾 𝑝 = Proportional gain
𝑥 𝑟 =
servo cylinder reference
position
𝑥 𝑎 = servo cylinder actual position
𝐹𝑟 = Reference loading force
𝐹𝑎 = Actual loading force
Linear System Model
𝑦 + 2ζ 𝑠 𝜔0𝑣 𝑦 + 𝜔0𝑣
2
𝑦 = 𝜔0𝑣
2
𝐾0𝑣 𝑖
 The dynamic model of the valve spool can
be approximated to a second order transfer
function without serious loss of accuracy
𝑖 = 𝐾 𝑝 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔
∗ (𝑥 𝑟 − 𝑥 𝑎)
𝑖 = 𝐾 𝑝 𝑙𝑜𝑎𝑑𝑖𝑛𝑔
∗ (𝐹𝑟 − 𝐹𝑎)
 The controller used is a proportional
controller to compensate for the time lag
and amplitude shift between the reference
and command values
Slide 19/58

20. Master Thesis Defense
Khaled H. Emam
Linear System Model
 The non-linear flow rate load characteristic (QL = f(y,PL)) is a function in two
variables. Taylor expansion of the function is applied for each variable taking the
working point at y = ywp & PL = PLwp.
Flow rate gain : KQy
=
𝜕QL
𝜕y
|PLwp
=
𝑄0 𝑚𝑎𝑥
𝑦 𝑚𝑎𝑥
. 1 − 𝑠𝑔𝑛 𝑦 .
PLwp
𝑃𝑜
Load gain : KQp
=
𝜕QL
𝜕PL
|ywp
=
−
𝑄0 𝑚𝑎𝑥
2𝑃𝑜
.
ywp
𝑦 𝑚𝑎𝑥
1
1−𝑠𝑔𝑛 ywp .
PL
𝑃 𝑜
 The linearization is calculated at the working
points (ywp=0 & PLwp
=0)
QL.linearized = KQy
. 𝑦 + KQp
. PL
Introduction
Mechanical
Design
Hydraulic
Design
Controller Design Data Acquisition Results Conclusion
Slide 20/58

21. Master Thesis Defense
Khaled H. Emam
Linear System Model
 The flow continuity equation for the cylinder chamber is given by:
𝑃𝐿 = 𝑃𝐴 − 𝑃𝐵 =
2𝐸
𝑉𝐶
QL.linearized − 𝐴 𝑝 𝑥′ − GLint
. PL
 The piston equation of motion is as follows
where d is the Viscous Friction Coefficient
𝑚x + d 𝑥 = 𝑃𝐿 𝐴 𝑐 − 𝐹𝑙𝑜𝑎𝑑
where GLint is the Coefficient of internal leakage
𝐴 𝑐 is the cylinder cross-sectional area
Introduction
Mechanical
Design
Hydraulic
Design
Controller Design Data Acquisition Results Conclusion
Slide 21/58

22. Master Thesis Defense
Khaled H. Emam
Linear System Model
Hydraulic transfer function:
𝐺 𝐻 𝑠 =
𝑃𝐿
KQy
− 𝐴. 𝑥
=
2𝐸
𝑉 .
1
𝑠
1 +
2𝐸
𝑉
.
1
𝑠
. (KQp
+ GLint
)
Mechanical transfer function:
𝐺 𝑀 𝑠 =
𝑥
𝑃𝐿 −
𝐹
𝐴
=
𝐴
𝑚
.
1
𝑠
1 +
𝐴
𝑚 .
1
𝑠 .
𝑑
𝐴
Introduction
Mechanical
Design
Hydraulic
Design
Controller Design Data Acquisition Results Conclusion
Slide 22/58

23. Master Thesis Defense
Khaled H. Emam
Linear System Model
𝐾 𝑀 =
𝐴
𝑑
, 𝑇 𝑀 =
𝑚
d1/𝐾 𝐹𝐵
𝐺 𝑀 𝑠 =
𝑥
𝑃𝐿 −
𝐹
𝐴
=
𝐾 𝑀
1 + 𝑠. 𝑇 𝑀
𝐺 𝐻 𝑠 =
𝑃𝐿
KQy
− 𝐴. 𝑥
=
𝐾 𝐻
1 + 𝑠. 𝑇 𝐻
𝐾 𝐻 =
1
KQp
+ GLint
, 𝑇 𝐻 =
𝑉
2. 𝐸
.
1
KQp
+ GLint
Introduction
Mechanical
Design
Hydraulic
Design
Controller Design Data Acquisition Results Conclusion
Slide 23/58

24. Master Thesis Defense
Khaled H. Emam Slide 24/58
Introduction
Mechanical
Design
Hydraulic
Design
Controller Design Data Acquisition Results Conclusion
Linear System Model
0 0.2 0.4 0.6 0.8 1
-4
-3
-2
-1
0
1
2
3
4
x 10
-3
time (sec)
Hydraulic Mould Oscillator
PistonDisplacement(m)
linear valve model
detailed valve model
• The Hydraulic
Mold Oscillator is
used as a model
to validate results.
• Comparison
between detailed
and linear models
shows
convergence
between results

25. Master Thesis Defense
Khaled H. Emam
Linear System Model
Introduction
Mechanical
Design
Hydraulic
Design
Controller Design Data Acquisition Results Conclusion
Slide 25/58
Forster, I. (1984). Electro-hydraulic Load Simulator. o+p Oil hydraulics
and pneumatics, 8 (28).

26. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller Design Data Acquisition Results Conclusion
𝑮 𝒙 𝒔 = 𝑲 𝒑 𝒐𝒑𝒆𝒓𝒂𝒕𝒊𝒏𝒈
. 𝑮 𝒗𝒂𝒍𝒗𝒆 𝒐𝒑𝒆𝒓𝒂𝒕𝒊𝒏𝒈 𝒔 . 𝐊 𝐐 𝐲
. 𝑮 𝒛 𝒔 .
𝟏
𝒔
• 𝐺 𝑣𝑎𝑙𝑣𝑒 𝑠 =
𝐾 𝑣.𝜔 𝑜𝑣
2
𝑠2+2ζ 𝑠 𝜔 𝑜𝑣 𝑠+𝜔 𝑜𝑣
2
• 𝐺𝑧 𝑠 =
𝐺 𝐻 𝑠 .𝐺 𝑀 𝑠 .𝐴 𝐶 𝑜𝑝
1+𝐺 𝐻 𝑠 .𝐺 𝑀 𝑠 .𝐴 𝐶 𝑜𝑝
2 =
𝐾 𝐻.𝐾 𝑀.𝐴 𝐶 𝑜𝑝
1+𝑇 𝐻.𝑇 𝑀 𝑠2+ 𝑇 𝐻+𝑇 𝑀 𝑠+𝐾 𝐻.𝐾 𝑀.𝐴 𝐶 𝑜𝑝
2
Linear System Model
Operating side open loop transfer function
∴ 𝑮 𝒙 𝒔 =
𝐾𝑣. 𝜔 𝑜𝑣
2
𝐾 𝐻. 𝐾 𝑀. 𝐴 𝐶 𝑜𝑝 𝐾 𝑝 𝑜𝑝
𝐾 𝑄 𝑦
𝑠 𝑠2 + 2𝑠ζ 𝑠 𝜔 𝑜𝑣 + 𝜔 𝑜𝑣
2
1 + 𝑠𝑇 𝐻 + 𝑠𝑇 𝑀 + 𝑠2 𝑇 𝐻 𝑇 𝑀 + 𝐾 𝐻 𝐾 𝑀 𝐴 𝐶 𝑜𝑝
2
The open loop characteristic equation is as follows:
411411𝑠 +6526.23𝑠2
+36.8171 𝑠3
+0.0922355 𝑠4
+0.00010812 𝑠5
+2402.82 𝐾 𝑝 𝑜𝑝
=0
Slide 26/58

27. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller Design Data Acquisition Results Conclusion
Linear System
Model
Operating side -
controller design
-300
-250
-200
-150
-100
-50
Magnitude(dB)
10
1
10
2
10
3
10
4
-450
-360
-270
-180
-90
Phase(deg)
Bode Diagram
Gm = 88.4 dB (at 108 rad/s) , Pm = 90 deg (at 0.00584 rad/s)
Frequency (rad/s)
Proportional gain limit
is calculated using
Routh-Hurwitz
criterion, bode plot and
root locus method.
Slide 27/58

28. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller Design Data Acquisition Results Conclusion
Linear System
Model
Operating side -
controller design
-1200 -1000 -800 -600 -400 -200 0 200 400 600
-1000
-500
0
500
1000
Root Locus
Real Axis (seconds-1
)
ImaginaryAxis(seconds-1)
Slide 28/58

29. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller Design Data Acquisition Results Conclusion
Linear System Model
Operating side - controller design
 Proportional gain limit is calculated using Routh-Hurwitz criterion, bode plot and root locus
method.
 This gain value shouldn’t exceed 𝐾 𝑝 𝑜𝑝
< 26 %/𝑚
 PID tuning techniques were applied to optimize the gain value.
Slide 29/58

30. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller Design Data Acquisition Results Conclusion
Linear System Model
Loading side open loop transfer function
𝐺 𝐹 𝑠 = 𝑲 𝒑 𝒍
∗
𝐾𝑣. 𝜔 𝑜𝑣
2
𝑠2 + 2𝐷𝑣 𝜔 𝑜𝑣 𝑠 + 𝜔 𝑜𝑣
2 ∗ 𝐊 𝐐 𝐲
∗
𝐾 𝐻
1 + 𝑇 𝐻. 𝑠
∗ 𝐴 𝑐𝑙
=
𝐾𝑣. 𝜔 𝑜𝑣
2 𝐴 𝑐𝑙 𝐾 𝐻 𝐾 𝑝 𝑙
𝐾 𝑄 𝑦
1 + 𝑇 𝐻. 𝑠 𝑠2 + 2𝑠𝐷𝑣 𝜔 𝑜𝑣 + 𝜔 𝑜𝑣
2
𝑇 𝐻. 𝑠3 + 𝑠2 1 + 2𝑇 𝐻 𝐷𝑣 𝜔 𝑜𝑣 + 𝑠 2𝐷𝑣 𝜔 𝑜𝑣 + 𝑇 𝐻 𝜔 𝑜𝑣
2 + 𝜔 𝑜𝑣
2 1 + 𝐾𝑣 𝐴 𝑐𝑙 𝐾 𝐻 𝐾 𝑝 𝑙
𝐾 𝑄 𝑦
= 0
0.000765. 𝑠3
+ 𝑠2
1.40376 + 𝑠 636.511 + (14400 π2
)[1 + 3635.74 𝐾 𝑝 𝑙
] = 0
The characteristic equation of the open loop transfer function is as follows:
Slide 30/58

31. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller Design Data Acquisition Results Conclusion
Linear System
Model
Loading side -
controller design
-300
-250
-200
-150
-100
-50
Magnitude(dB)
10
1
10
2
10
3
10
4
-450
-360
-270
-180
-90
Phase(deg)
Bode Diagram
Gm = 88.4 dB (at 108 rad/s) , Pm = 90 deg (at 0.00584 rad/s)
Frequency (rad/s)
Slide 31/58

32. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller Design Data Acquisition Results Conclusion
-5000 -4000 -3000 -2000 -1000 0 1000 2000
-3000
-2000
-1000
0
1000
2000
3000
Root Locus
Real Axis (seconds-1
)
ImaginaryAxis(seconds-1
)
Linear System
Model
Loading side -
controller design
Slide 32/58

33. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller Design Data Acquisition Results Conclusion
Linear System Model
Loading side - controller design
 The range of gain values for loading servos system is shown to be less than 1.98 %/𝑘𝑁
 PID tuning techniques were applied to optimize the gain value.
Slide 33/58

34. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
Slide 34/58

35. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
ADCH1 Not connected DACH1 Servovalve#1 Command Signal
ADCH2 Not connected DACH2 Not connected
ADCH3 Not connected DACH3 To DS-1104#2
ADCH 4 Not connected DACH4 To DS-1104#2
ADCH5 Position Sensor #1 WLH100 DACH5 Not connected
ADCH6 Servovalve#1 Feedback DACH6 Not connected
ADCH7 Not connected DACH7 Not connected
ADCH8 Not connected DACH8 Not connected
Slide 35/58

36. Master Thesis Defense
Khaled H. Emam
ADCH1 From DS-1104#1 DACH1 Servovalve#3 Command
ADCH2 From DS-1104#1 DACH2 Not connected
ADCH3 Servovalve#3 Feedback Signal DACH3 Not connected
ADCH4 Not connected DACH4 Not connected
ADCH5 Pressure Transducer EDS300 DACH5 Not connected
ADCH6 Position Transducer#3 WLH100 DACH6 Not connected
ADCH7 Not connected DACH7 Not connected
ADCH8 Not connected DACH8 Not connected
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
Slide 36/58

37. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
 Parameters:
• 𝐾 𝑝 𝑜𝑝
= 1
• Amplitude=3.5mm
• Freq. = 3Hz
Experiment 1:
0 0.5 1 1.5 2
-0.4
-0.3
-0.2
-0.1
0
0.1
0.2
0.3
0.4
0.5
time (sec)
SpoolDisplacement(mm)
Servo Valve Y
actual
Servo Valve Y
reference
Slide 37/58

38. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
 Parameters:
• 𝐾 𝑝 𝑜𝑝
= 1
• Amplitude=3.5mm
• Freq. = 3Hz
0 0.5 1 1.5 2
46
47
48
49
50
51
52
53
54
time (sec)
PistonDisplacement(mm)
Operating Cylinder X
actual
Operating Cylinder X
reference
Slide 38/58

39. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
 Parameters:
• 𝐾 𝑝 𝑜𝑝
= 25
• Amplitude=3.5mm
• Freq. = 3Hz
Experiment 2:
0 0.5 1 1.5 2
-1
-0.5
0
0.5
1
1.5
time (sec)
SpoolDisplacement(mm)
Servo Valve Y
actual
Servo Valve Y
reference
Slide 39/58

40. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
 Parameters:
• 𝐾 𝑝 𝑜𝑝
= 25
• Amplitude=3.5mm
• Freq. = 3Hz
0 0.5 1 1.5 2
46
47
48
49
50
51
52
53
54
time (sec)
PistonDisplacement(mm)
Operating Cylinder X
actual
Operating Cylinder X
reference
Slide 40/58

41. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
 Parameters:
• 𝐾 𝑝 𝑜𝑝
= 25
• Amplitude=3.5mm
• Frequency = 5Hz
Experiment 3:
0 0.5 1 1.5 2
-1.5
-1
-0.5
0
0.5
1
1.5
2
2.5
time (sec)
SpoolDisplacement(mm)
Servo Valve Yactual
Servo Valve Yreference
Slide 41/58

42. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
 Parameters:
• 𝐾 𝑝 𝑜𝑝
= 25
• Amplitude=3.5
• Frequency = 5 rad/s
0 0.5 1 1.5 2
46
47
48
49
50
51
52
53
54
time (sec)
PistonDisplacement(mm)
Operating Cylinder X
actual
Operating Cylinder X
reference
Slide 42/58

43. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
 Parameters:
• 𝐾 𝑝 𝑜𝑝
= 25
• Amplitude=5mm
• Frequency = 5Hz
Experiment 4:
0 0.5 1 1.5 2
-2
-1
0
1
2
3
4
time (sec)
SpoolDisplacement(mm)
Servo Valve Y
actual
Servo Valve Y
reference
Slide 43/58

44. Master Thesis Defense
Khaled H. Emam
 Parameters:
• 𝐾 𝑝 𝑜𝑝
= 25
• Amplitude=5mm
• Frequency = 5Hz
0 0.5 1 1.5 2
44
46
48
50
52
54
56
time (sec)
PistonDisplacement(mm)
Operating Cylinder Xactual
Operating Cylinder Xreference
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
Slide 44/58

45. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
 Parameters:
• 𝐾 𝑝 𝑜𝑝
= 32
• Amplitude= 3.5mm
• Frequency = 5Hz
Experiment 5:
0 0.5 1 1.5 2
-1.5
-1
-0.5
0
0.5
1
1.5
2
time (sec)
SpoolDisplacement(mm)
Servo Valve Y
actual
Servo Valve Y
reference
Slide 45/58

46. Master Thesis Defense
Khaled H. Emam
 Parameters:
• 𝐾 𝑝 𝑜𝑝
= 32
• Amplitude= 3.5mm
• Frequency = 5Hz
0 0.5 1 1.5 2
46
47
48
49
50
51
52
53
54
time (sec)
PistonDisplacement(mm)
Operating Cylinder X
actual
Operating Cylinder X
reference
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
Slide 46/58

47. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
 Parameters:
• 𝐾 𝑝 𝑜𝑝
= 45
• Amplitude= 5mm
• Frequency = 5Hz
Experiment 6:
0 0.1 0.2 0.3 0.4 0.5
-2
-1
0
1
2
3
4
time (sec)
SpoolDisplacement(mm)
Servo Valve Y
actual
Servo Valve Y
reference
Slide 47/58

48. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
 Parameters:
• 𝐾 𝑝 𝑜𝑝
= 45
• Amplitude= 5mm
• Frequency = 5Hz
0 0.1 0.2 0.3 0.4 0.5
44
46
48
50
52
54
56
time (sec)
PistonDisplacement(mm)
Operating Cylinder X
actual
Operating Cylinder X
reference
Slide 48/58

49. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
 Parameters:
• 𝐾 𝑝 𝑙
= 2.5
• Force signal:
Amplitude= 45 kN
Frequency = 0 Hz
0 0.005 0.01 0.015 0.02
40
45
50
55
time (sec)
Force(kN)
Force
act
Force
ref
Force control
Slide 49/58

50. Master Thesis Defense
Khaled H. Emam Slide 50/40
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
 Parameters:
• 𝐾 𝑝 𝑙
= 2.5
• Force signal:
Amplitude= 45 kN
Frequency = 0 Hz
Force control
0 0.005 0.01 0.015 0.02
-0.07
-0.06
-0.05
-0.04
-0.03
-0.02
-0.01
0
time (sec)
SpoolDisplacement(mm)
Servo Valve Y
actual

51. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
Study case
 Parameters:
• Zero input signal
• No load condition
Slide 51/58

52. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
Study case
0 0.2 0.4 0.6 0.8 1
-2
-1.5
-1
-0.5
0
0.5
1
1.5
2
time (sec)
SpoolDisplacement(mm)
Servo Valve Y
actual
Servo Valve Y
reference
 Parameters:
• 𝐾 𝑝 𝑜𝑝
= 32
• Amplitude= 3.5mm
• Frequency = 5Hz
Slide 52/58

53. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
0 0.2 0.4 0.6 0.8 1
46
47
48
49
50
51
52
53
54
time (sec)
PistonDisplacement(mm)
Operating Cylinder X
actual
Operating Cylinder X
reference Parameters:
• 𝐾 𝑝 𝑜𝑝
= 32
• Amplitude= 3.5mm
• Frequency = 5Hz
Study case
Slide 53/58

54. Master Thesis Defense
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
Conclusion
 The proposed design of the hardware in the loop test rig was discussed throughout the thesis.
 The mechanical, hydraulic, electrical and electronic interfaces and the control algorithm were
presented throughout the study.
 The experimental measurements validate the implemented software model and theoretical
calculations of the system.
 The device can also be used to test the time response for standard directional
hydraulic valves without the need to connect a controller.
Slide 54/58

55. Master Thesis Defense
Khaled H. Emam
Introduction
Mechanical
Design
Hydraulic
Design
Controller
Design
Data Acquisition Results Conclusion
Recommendation for future work
 The test rig can be used to test the time response for standard directional hydraulic valves
without the need to connect a controller.
 This study is considered the first step towards manufacturing a servo cylinder test rig in the
GUC.
 Future work should be directed towards implementing the controller using modern control
approach or fuzzy logic control.
Slide 55/58

56. Master Thesis Defense
Khaled H. Emam
Thanks for listening
Your questions & feedback are highly appreciated
Khaled Hossam Emam
khaled.fouad@guc.edu.eg
Acknowledgement
Slide 56/58

57. Master Thesis Defense
Khaled H. Emam
Proportional controller tuning:
0 0.1 0.2 0.3 0.4 0.5
0
0.5
1
1.5
time (sec)
CylinderStroke(mm)
ISE
IAE
ITSE
ITAE
Ziegler-Nichols
Slide 57/58

58. Master Thesis Defense
Khaled H. Emam
PID -controller tuning:
0 0.1 0.2 0.3 0.4 0.5
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
time (sec)
Cylinderstroke(mm)
ISE
IAE
ITSE
ITAE
Ziegler-Nichols
Slide 58/58