Synchronization Control System Design

Of 80MN Hydraulic Press

ZHANG Guanghong
Shanxi Institute of Mechanical & Electrical Engineering, Shanxi Changzhi, China
Email: zghzghzgh@sohu.com
AbstractA fuzzy control method combined with PID
control strategy is proposed in the paper. The research
focuses on the 5 hydraulic-cylinder of a 10000-ton hydraulic
press control system . Experiment results prove that the
employed control method succeeds in controlling the 5
hydraulic-cylinder of a 10000-ton hydraulic press.
Index Termsfuzzy control, synchronization control, PID
. INTRODUCTION
THP10-10000-ton numerical control and isothermal
Titanium hydraulic forging press is an important
equipment which is use in the development of new type
of aviation technology . It is also true to the new
process of isothermal super plastic molding for aircraft
material and is the same with nonferrous metal, military
hardware, shipping, Chemical Machinery ,etc. This
machine adopts new and large combined core structure
with framework of hydraulic ram lift sliding block which
is driven by 5 hydraulic-cylinder. The master cylinder
is a single cylinder which can produce 60M Newton
pressure ( in the center of the sliding block) ,the
auxiliary cylinder is 4 single cylinders which can
produce 10M Newton pressure ( at the four-corner of
the sliding block) , with general operating oil pressure
25Mpa, with the highest operating oil pressure
31.5Mpa .This machine requires 5 Hydraulic-cylinder
Synchronization during the isothermal forging press , and
simultaneously the position of Synchronization control
accuracy should be less than 0.1mm/m, that is, the error
between 2 auxiliary cylinders cant be over 0.1mm when
they are far from 1m.
II. SYSTEM DESIGN
A. System Analysis
In the system of Hydraulic Power transmission , the
requirement of Synchronization Control is common, but
synchronization with huge flow rate, high degree of
accuracy and numerous actuators is always a difficult
problem .Due to the characters of hydraulic system, such
as liquid squeeze, leakiness, damp , etc, especially with
the factors of larger outer capacity, changeable outer
capacity, lack of balance of equipment and larger travel
of equipments motion, its hard to realize a higher
Synchronization control accuracy of several cylinders. So
the search of design plan, control method, and
synchronization of synchrony system will influence
the operating condition of hydraulic press.
This system requires not only Synchronization speed
of 5 cylinders but also a larger change range of flow, so
the system is a Synchronization control system with
changeable flow and higher accuracy. According to
Principle of Hydraulics, electric control system has two
kinds: valve control and pump control. The former is of
higher accuracy and faster response speed , so this system
adopts valve control .
According to Principle of Hydraulics, hydraulic
cylinder isnt integral when the speed of valve control
hydraulic cylinder is for export, so hydraumatic Speed
Control System is of property, not integral , and its
open-cycle transfer function approximation
[1]
Figure 1 Hydraulic Press Working Principle
ISBN 978-952-5726-06-0
Proceedings of the 2009 International Workshop on Information Security and Application (IWISA 2009)
Qingdao, China, November 21-22, 2009
2009 ACADEMY PUBLISHER
AP-PROC-CS-09CN004 488
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So, the base of hydraulic synchronization control
system is control system on single hydraulic systems ,
while proportion of position control is nonlinear and
time-varying volatility. Many parameters is nonlinear
due to working condition, such as different working point,
speed gain change , damping ratio , in addition , mutual
influence in motion between 5 cylinders , so to build
accurate math model of synchronous process is difficult.
In the motion the real potion of master cylinder cant be
checked because it is in the center of the sliding block; on
the other hand, the master cylinder produces main
pressure of work, if not well controlled, it may cause
some auxiliary cylinder follows to move, which may
result in invalidation of its regulating effect , even
destroy the whole Synchronization, so control of master
cylinder will have immediate impact on the function of
the whole system. So in the control system, electro
hydraulic proportion position system is controlled by the
way of linearized model , which cant get satisfied
control effect. So the system design adopt the
combination of fuzzy control and PID control. Figure 1:
synchronization circuit elementary diagram of 5 cylinders.
When the system is working, the value of displacement
transducer connected to 4 auxiliary cylinders, that is ,
motion displacement value of 4 cylinders. Based on the
motion displacement value of Cylinder 1 , comparing it
with Cylinder 2 ,Cylinder 3, Cylinder 4 , and we get the
deviation displacement value of every Cylinder.
Displacement error will be eliminated after the opening
flow rate of proportional valve is controlled by numeral
PID; the master cylinder and No.1 auxiliary cylinder is
controlled by FuzzyPID controller, by this way the
whole system can arrive the best condition.
B. PID Control Principle
In the analog control system, common control rule is
PID Control.PID controller is a kind of linear controller
[2]
,
and it forms error according to the given value rtand
the real output value ct:
( ) ( ) ( ) t c t r t e =
Ratio of the errorP, integralIand differential
Dforms controlled quantity, and control the controlled
item, so its called PID Control. The control rule is
( ) ( ) ( )
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Simply speaking, the effect of every correcting link of
PID controller is the following: Proportional Component
deviation signal of control system is reflected
proportionally and immediately. Deviation once comes
about, controller will work to decrease the deviation.
Integrating Element It is mainly used to eliminate the
offset, and improve the isoch level . Strong or weak
integrating effect depends on integration time constant.
Differentiation Element It can reflect change trend of
deviation signal deviation signal . If the deviation signal
becomes too big, it can draw into an early revising signal
to make the system speed up , and shorten the
regulating time.
Because computer control is sampling control, it can
calculate the value according to the sampling deviation
value, the Integration and Differentiation items cant be
used directly, which need discretization process . With
a set of sampling time kT instead of constant time t , with
summation formula instead of integration, and increment
instead of differentiation, analog PID expression is dealt
with, disperse expression of PID control algorithm is the
following
[3][4]
:
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+ + =

=
k
j
D
I
P
k e k e
T
T
j e
T
T
k e K k u
0
1
u(k) Value output by computer control actuator ( e.g.
valve) .As numeral PID control is realized by computer
program , some parameters can be set and handled
optimally. Numeral PID control is a common control
method during production, which is widely used in the
fields of metallurgy, machine and chemical engineering.
C. Fuzzy-PID Control
Fuzzy Control is a kind of intelligent control based
on Fuzzy Set Theory, fuzzy language variation and fuzzy
logical reason. Its basic concept is firstly put forward by
famous professor L A Zadeh of University of
California of America, and the theory and practice
research both get big success after long development.
As Fuzzy Controller neednt master exact math model
of the controlled object, it must be an effective way for
some complex system that is hard to set up exact math
model for largely lagging, time-changing, and nonlinear
course during industry controlling process. Fuzzi PID
Controller developed in the recent years combines fuzzy
control and PID control, which is flexible like fuzzy
control and exact like PID control, so it has good
controlling effect for complex system and servo system
with high accuracy.
In the paper the participle of Fuzzyi PID Controller
in connection with the master cylinder and No.1 auxiliary
cylinder, a value is set according to real control accuracy.
When the real value is greater than the value, the ontroller
will control the master cylinder and No.1 auxiliary
cylinder based on No.2 auxiliary cylinder No.3 auxiliary
cylinder No.4 auxiliary cylinder lest uncontrolled
condition; in the contrast when the real value is less than
the value PID Control will improve the control accuracy.
In the practical design, we adopt separation trait of
fuzzy controller, separate the structure of controller into
some multiple input--- single output model controller, and
design it with the method of univariate fuzzy controller.
489
As Fuzzy Controller is the core of fuzzy control system,
the structure of Fuzzy Controller, adoptive fuzzy rules ,
compound reasoning algorithm and the way of fuzzy
decision and so on will decide the function of a fuzzy
control system. So the determination of variable universe
of discourse, selection of membership function and
choice of fuzzy method have been obtained after many
experiments.
. EXPERIMENTAL VERIFICATION
A. No Load Test
Figure2 shows the graph of maximal synchronization
error when hydrostatic press with no load goes down in
low speed, ordinate axis is for maximal error, unit: mm,
o 4.80e+0p refers to the present coordinate is 4.80mm;
abscissa axis is for time, showing the present time. From
he printed maximal error graph , we can know maximal
error is about 5mm, the controller begins to adjust the
synchronization of 5 cylinders, the synchronization
error will get to zero after 2 minutes; Although there is
some fluctuation and costs more time, the general trend
and adjustment time accords with the analysis, and the
last synchronization result entirely meet the demands.
B. Load Experiment
Figure3 shows the graph of maximal error recorded
when hydrostatic press is working . During the process, if
the Synchronization function is closed, the
Synchronization deviation will gradually augment. This
deviation will affect quality of forming work piece , and
will threaten the service life and using safety of the
whole system. When maximal Synchronization error
approaches 4mm, with Synchronization control
connected, the maximal Synchronization error will lower
quickly, even get to zero. It can be seen that
Synchronization time is shorter when hydrostatic press
works with load than no load, which is related to the
design the whole hydrostatic press system. As the longest
distance between two cylinders of hydrostatic press is
Figure2 No-Load RT Graph
Figure3 Load RT Graph
Figure4
490
about 4m, it can be in the best condition when maximal
Synchronization error is less than 0.4mm, but the real
synchronization accuracy is usually better than the index.
Because we use1micrometer precisions linear scale to
detect the position of hydrostatic press , we can observe
the graph near zero coordinate position after change of
coordinates .As shown in Figure 4, o 2.00e-1p means
the coordinate figure is 0.2mm. when maximal
Synchronization error drops down to 0.4mm and continue,
until it keeps about 0.03mm. That is , when the horizontal
position is 4m. the maximal Synchronization error will
keep about 30 micro meters.
. CONCLUSION
From the result of the experiment, the Design of
Synchronization Control System of the Hydraulic Press is
successful , it has a good function since it began to use in
some large aviation forging base, with a good effect.
REFERENCES
[1] Lu Changeng Analysis and Design of Hydraulic Control
System. Beijing: Coal Industry Press.1991.
[2] Tao Yonghua Control and Application of New PID.
Beijing: China Machine Press. 2002.
[3] Yu Zhongyuan Industrial Process Control Computer
System. Beijing: Beijing Institute of Technology
Press,1995.
[4] Guo Jingshu Control Technique of Microcomputer.
Chongqing : University Of Chongqing Press. 1994.
[5] Li Shiyong Fuzzy Control and Intelligent Control
Theory and Applications. Haerbin: Harbin Institute of
Technology Press, 1990.
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