MEC-E5004 - Fluid Power Systems

Simscape Fluids exercise

Simscape is an environment for modeling and simulating multidomain physical systems within
Matlab/Simulink. More than 10 physical domains, including mechanical, electrical and hydraulic (Simscape
Fluids) are covered. In this assignment both the Simscape Fluids and Simulink domains are mostly utilized.

With Simscape physical component models can be generated based on physical connections by using physical
units for both parameters and variables. All unit conversions are handled automatically.

Cylinder piston’s position can be controlled in open

and closed loop by using directional proportional
control valve. System includes
• Differential cylinder with inertia load (mass)
• Directional proportional control valve
• Pressure compensated pump (constant pressure)
• Control system for position control
• (Presure relief valve)
Hydraulic actuator force needed only for mass
acceleration and deceleration since there is no
mechanical friction in this system.
In the assignment the cylinder piston is moved
a) into – direction and b) into + direction
The hydraulic system to be modeled both by using a) open loop and b) closed loop control.

Open Matlab.

Open the Simscape model template for your Simscape Fluids models.

For opening give Matlab command

ssc_new

This will open the

 Model template with

o Solver Configuration block to specify the solver parameters for your model
o Simulink-PS Converter and PS-Simulink Converter blocks for data transfer
between Simscape and Simulink domains
 Foundation library

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You can enter Matlab command SimscapeFluids_lib for Simscape Fluids block library.

Library: SimscapeFluids_lib

Library: SimscapeFluids_lib > Hydraulics (Isothermal)

Model canvas

Open loop control – assignment phase 1

Find Hydraulics (Isothermal) > Hydraulic Utilities library, open it (double clicking) and use the
mouse to drag a Hydraulic Fluid block to your new model canvas.
With this block you can determine the physical properties of the hydraulic fluid.
 density,
 viscosity, and
 bulk modulus.

1. Open Hydraulic Fluid block by double clicking it.

2. Change the Hydraulic Fluid from Skydrol LD-4 to ISO VG 32 (ESSO UNIVIS N 32).
3. Keep the other fluid parameters the same.
Skydrol is fire-resistant aviation hydraulic fluid: http://skydrol-ld4.com/technical_bulletin_skydrol_4.pdf.

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 Connect the Solver Configuration (f(x)=0) and Hydraulic Fluid blocks.

 With left mouse button draw a wire between blocks’ terminals.

 OR
 Click on the first block with the left button of your mouse
 Press Ctrl button of your keyboard
 Click on the second block
 Connection (Wire) will be formed automatically.

Solver Configuration Hydraulic Fluid

The Solver Configuration block defines solver settings for your model.

Attention! You can rotate blocks by using Crtl-R keyboard command.

In your canvas window click Library Browser button to open Simulink Library Browser.

From the Simulink Library Browser’s Simscape > Foundation library

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Pick the next two blocks and drag them to the model canvas.

Block From Sublibrary

Hydraulic Constant Pressure Source Foundation Library > Hydraulic > Hydraulic Sources
Hydraulic Reference Foundation Library > Hydraulic > Hydraulic Elements

Hydraulic Constant Pressure

Source and
Hydraulic Reference

The Hydraulic Reference block represents a connection to atmospheric pressure.

Connect these elements on the canvas. To make the branch use mouse’s right button.

Simscape Fluids Hydraulics (Isothermal)

From the Simscape > Fluids library, pick and drag two blocks to the model canvas.

Block From Sublibrary

Double-Acting
Hydraulic Cylinder Hydraulics (Isothermal) > Hydraulic Cylinders
(Simple)
4-Way Directional Valve Hydraulics (Isothermal) > Valves > Directional Valves

 The block connections represent the physical connections between the actual components. The
cylinder connects to the valve, which connects to the pump, which in turn connects to the fluid
reservoir.

 From the Simscape > Foundation > Mechanical > Translational library, add a Mechanical
Translational Reference block

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and connect it as shown in the figure below.

 Connect the 4-way Directional Valve to the Double-Acting Hydraulic Cylinder as

follows.

 From the Simscape > Foundation > Mechanical > Translational Elements library, add a
Mass block and connect it as shown in the figure below.

 From the Simscape > Foundation > Mechanical > Mechanical Sensors library bring an
Ideal Translational Motion Sensor block and connect it as in the figure below (both C and
R terminals).

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 Connect the Ideal Translational Motion Sensor block to PS-Simulink Converter and
Scope as follows.
Velocity
Position

 From the Hydraulics (Isothermal) > Valves > Valve Actuators library bring a Valve
Actuator block and connect it to Simulink-PS Converter and 4-Way Directional Valve as
in the figure below.

Valve Actuator Block

 Connect the 4-Way Directional Valve to Hydraulic Constant Pressure Source block and
to the Hydraulic Reference block as in the figure below.

Pressure sensors

for measuring cylinder chamber pressures.

 From the Simscape > Foundation library bring Hydraulic > Hydraulic Sensors >
Hydraulic Pressure Sensor block. Make a copy of it (Ctrl-C and Ctrl-V) and connect those

- between Hydraulic Cylinder’s A interface and Hydraulic Reference (B interface)

- between Hydraulic Cylinder’s B interface and Hydraulic Reference (B interface)

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 Connect both of the Hydraulic Pressure Sensor(s) to Scope(s) by using a PS-Simulink

Converter as follows. You can use the existing converter and make a copy of it.

Signal inputs

From the Simulink Library Browser > Sources bring

Step block  clone it (Ctrl-C and Ctrl-V) to get 4 blocks together.

Constant block

From the Simulink Library Browser > Math Operations bring

Add block

Connect the blocks with Simulink-PS Converter block as follows.

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Constant (named U_0) block represents the valve’s

zero point parameter. At first set the Constant
value to 0.

Adjust that parameter later to keep cylinder still

during zero input signal.

The Step blocks are used for step input commands

for the proportional control valve. These parameters
values will also be set later.

Pipes

From the Library: Simscape > Fluids > Hydraulics (Isothermal) > Pipelines bring Hydraulic
Pipeline block.

Make a copy of it and connect those two to Hydraulic Cylinder’s A and B interfaces and
corresponding A and B interfaces of 4-Way Directional Valve as in the figure below.
Attention! Remember that you can rotate blocks by using Crtl-R keyboard command.

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System Parameters

Double click blocks to open

Set system parameters as follows.

Step blocks for timing of the valve commands (usable voltage area: -10 V … 0 … +10 V).

Valve commands [V]

U [V] 3
2
1
0
0 2 4 6 8 10
-1
-2
-3

t [s]

Set Time and Final value

Step block 1 parameters

Set Time and Final value

Step block 2 parameters

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Set Time and Final value

Step block 3 parameters

Set Time and Final value

Step block 4 parameters

Constant (named U_0) block represents the valve’s zero point parameter. Run the simulation
(after setting other parameters) and adjust that parameter to keep cylinder still during zero input.

Valve Actuator

- maximum Valve stroke 0.005 m (5 mm)

o by applying 10 V input the Actuator reaches full 5 mm stroke
- therefore the Actuator gain is 0.005/10 [m or in theory m/V]
- the value for the Time constant can be 0.002 s (2 ms)

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Hydraulic Constant Pressure Source (ideal constant pressure pump)

- ideal pump with constant pressure of 120 bar (120105 [Pa] in Matlab: 120e5 [Pa])

4-Way Directional Valve (proportional valve)

For a narrow (mainly turbulent flow) orifice the flow rate is

If we know
2∆𝑝 - nominal flow rate (qv),
𝑞v = 𝐶q 𝐴√
𝜌 - nominal pressure drop (p),
- fluid density () and
- flow coefficient (Cq)

𝑞v the corresponding flow area can be calculated as

𝐴=
2∆𝑝 follows
𝐶q √ 𝜌

For leakage of a certain proportional control valve

qv 0.45 l/min  0.45/60000 m3/s

p 50 bar  50105 Pa

 844.4 kg/m3 (from Hydraulic fluid block for ISO VG 32 hydraulic fluid at 60C)

Cq 0.7 (for turbulent region)

Open the 4-Way Directional Valve block dialog box by double clicking.

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Set the Leakage area parameter as follows.

Leakage area parameter (0.45 l/min @ p= 50 bar over each control edge), use Copy+Paste.

0.45/60000/(0.7*sqrt(2*50e5/844.4))

In Model Parametrization page

Maximum opening parameter 0.005 m

Maximum opening area parameter, use Copy+Paste

Actual flow area (40 l/min @ 35 bar) + Leakage area +

40/60000/(0.7*sqrt(2*35e5/844.4))+0.45/60000/(0.7*sqrt(2*50e5/844.4))

Simscape’s way of modeling orifice area

𝐴maximum
𝐴orifice = ℎ + 𝐴leakage
ℎmaximum

h orifice opening [m]

hmaximum maximum orifice opening [m]

Amaximum maximum orifice area [m2]

Aleakage leakage orifice area [m2]

Leakage orifice area is for a “closed orifice”.

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Double-Acting Hydraulic Cylinder (Simple)

- D cylinder diameter 32 mm
- d rod diameter 20 mm
- Piston area A: pi/4*0.032^2 (AA= /4D2)
- Piston area B: pi/4*0.032^2- pi/4*0.020^2 (AB= AA -/4d2)
- Piston stroke: 1 m (maximum stroke)
- Piston initial distance from cap A: 0.8 m (initial position of piston)

Mass

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Pipe parameters

Update parameters
- Pipe internal diameter  0.012 m
- Pipe length  0.75 m

Ideal Translational Motion Sensor

Update parameter Initial position  0.8 m

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Your system should look like this. Start simulation

Your model should be ready for 10 s simulation.

Use scopes
 x
 p_A
 p_B
for piston position [m], A chamber pressure [Pa] and B chamber pressure [Pa].

You can also test if the input commands are correct by placing a Scope between Add block and
Simulink-PS Converter.

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Assignment for phase 1 – Open loop control

Make a short document (Word- > pdf)

Documentation Format:

Your name
Assignments
1. Finalize the simulation model
a. Document part 1
i. Paste a Figure of the System Model to your document
ii. Edit > Copy Current View to Clipboard > Metafile or Bitmap
2. Tune the system with valve’s zero point parameter (U_0). Adjust that parameter to keep
cylinder still during zero input.
a. Document part 2
i. Give the proper parameter value for U_0
3. Plot the Piston Displacement signal
a. Document part 3
i. Copy the Scope plot and paste it into your document
ii. File > Copy to Clipboard (Ctrl-C) OR
iii. (File > Print to Figure) OR
iv. Configuration Properties > Logging > Log data to Workspace
1. Variable name x
2. Save format: Array
3. In Matlab workspace
a. figure
b. plot(x(:,1),x(:,2));
4. Plot the Cylinder Pressure A signal
a. Document part 4
i. Copy the Scope plot and paste it into your document
ii. File > Copy to Clipboard (Ctrl-C) OR the options presented above
5. Plot the Cylinder Pressure B signal
a. Document part 5
i. Copy the Scope plot and paste it into your document
ii. File > Copy to Clipboard (Ctrl-C) OR the options presented above
6. Improvement suggestions to this Tutorial document
a. Actual errors or misprints (page and location)
b. Missing information
c. Actual improvements

Additional material
Getting started
https://se.mathworks.com/help/physmod/hydro/getting-started-with-simhydraulics.html
Simple actuator model tutorial
https://se.mathworks.com/help/physmod/hydro/ug/creating-a-simple-model.html

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Closed loop control – assignment phase 2

Remove blocks Step 2 and U_0.

Open block Add block change the List of signs to +-.

Rename the block to Error. Delete Step blocks 2, 3, and 4. Delete Constant block (U_0).

Open Step 1 block. Rename it as Step and update the parameter values as in the figure below.

Update cylinder parameters

Double click Double-Acting Hydraulic Cylinder (Simple) to open it.
Update Piston stroke and Piston distance from cap A as follows. Click OK.

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Update also Ideal Translational Motion Sensor. Set Initial position to 0.

From the Simulink > Math operations bring Gain block. Place it between Error and Simulink-
PS Converter as in the figure below. Name it as P gain. This is the system’s P controller (PID).

Branch (mouse right button) and connect Piston displacement signal wire from block PS-Simulink
Converter ….

to Error block’s second interface. The difference between the values tells you how far the actual
position is from the target position.

From Simulink > Signal routing library bring Mux (multiplexer) block.

Connect Scope block to it and name it for example as Piston Displacement - Command and
Position.
Connect wire from Step block to the first interface and Piston displacement signal to the second
interface.

From: Step
From: Piston displacement (x)

From Simulink > Sinks library bring To Workspace block.

Connect wire from Mux signal(s) to its interface.

Double click to open To Workspace block.

Adjust the parameter(s) as follows > Variable name > x. Click OK.

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Add also a Scope for valve command voltage U between P Gain and Simulink-PS Converter.

Your system should look (something like) this.

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Plotting of variables
File > Model properties > Model properties > Callbacks > StopFcn

Add the following code to StopFcn

close all
figure
plot(x.Time-3,x.Data(:,1))
hold on
plot(x.Time-3,x.Data(:,2))
%plot(x.Time-3,1+0*x.Time)
plot(x.Time-3,0.95+0*x.Time)
plot(x.Time-3,1.05+0*x.Time)
legend('command','x','95%','105%','Location','southeast')
Click OK to confirm the changes.

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Run the model.

You should get also a Figure like this.

Can be also here (depending on Matlab version)

Zoom
Data Cursor

Use Zoom (In or Out) and Data Cursor tools for finding detailed information.

Check from the Figure or from Scope Piston Displacement - Command and Position how well the
actuator follows the command.
If the performance is poor increase the P Gain value. Raise the value boldly (decades). This is only
a simulator!
Notice that the Piston displacement signal starts to oscillate if the P Gain value is too high.
More specified servo tuning instructions below (Tuning the P controller according to Ziegler-
Nichols).

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Tuning the P controller according to Ziegler-Nichols

- Increase P Gain parameter value until the system starts to oscillate continuously. Use
zooming!
- This minimum value of P Gain (parameter KP) is so called critical gain KP, crit. Store
this value!
- (To implement controllers as PI or PID you should also estimate the time period of
oscillation Tcrit corresponding this gain. This can be identified from the response  time
between two successive peaks).
- P controller’s gain according to Ziegler-Nichols tuning rules is now simply 0.5KP, crit.

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Assignment for phase 2

Continue with your short document (Word -> pdf) for Phase 1

Documentation Format:

Assigments

- Finalize the simulation model

 Paste a Figure of the updated simulation model to your document
 Edit > Copy Current View to Clipboard > Metafile or Bitmap
- Test the system with critical gain and two different values for the P gain
o Pgain, 0= KP, crit (critical gain according to Ziegler-Nichols tuning rule)
o Pgain, 1= 0.5KP, crit (tuned according to Ziegler-Nichols tuning rule)
o Pgain, 2= 0.25KP, crit (smaller gain for comparison)

- Plot the Piston Displacement signals for

 Pgain, 0 (critical)
1. overall displacement Figure
2. zoomed Figure to see the performance near the target position
 Pgain, 1
3. overall displacement Figure
4. zoomed Figure to see the performance near the target position
 Pgain, 2
1. overall displacement Figure
2. zoomed Figure to see the performance near the target position

Analyze the plots and add information to these tables. Check the following page for Performance
analysis.

P controller parameters
KP, crit V/m
0.5KP, crit V/m
0.25KP, crit V/m

Performance of P control for Pgain, 1 parameter value (0.5KP, crit)

Overshoot %
Rise time 95% s
Settling time 5% s
Steady state error m

Performance of P control Pgain, 2 for parameter value (0.25KP, crit)

Overshoot %
Rise time 95% s
Settling time 5% s
Steady state error m

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Overshoot
The ratio of difference between output y’s first maximum and its new steady-state value to its new
steady-state value (= a/b in Figure above). Sometimes this characteristic is marked with Mp,
maximum percentual overshoot.
Rise time (95%)
Time it takes for the response to rise from zero to 95% of the steady-state response.
Damping ratio
The ratio of difference between output y’s first maximum and its new steady-state value to the
difference between output y’s second maximum and its new steady-state value (= c/a in Figure
above).
Settling time ts
The time that after a stepwise change in system’s setting value w is required for the process output y
to reach and remain inside a band whose width is equal to ±5 % of the total change in y (sometimes
also other bandwidths are used, e.g., ±1 %, ±2 %).
Time period T
The time between output y’s two successive peaks (e.g., first and second maximum) or valleys.
Oscillation frequency f
The frequency that the system oscillated with (= 1/T).
Steady state error est
The constant deviation between system’s setting value w and actual output value y.

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