Pneumatic and Hydraulic controllers
Reference:
Chapter-4, Modern Control Engineering
(K. Ogata)
Introduction
The term pneumatic describes fluid systems that use air or gases and hydraulic applies to those
using oil.
Both pneumatic systems and hydraulic systems can be modeled easily by using the concepts of
resistance and capacitance.
Comparison Between Pneumatic Systems and Hydraulic Systems
Air and gases are compressible, whereas oil is incompressible, (except at high pressure)
Air lacks lubricating property and always contains water vapor. Oil functions as a
hydraulic fluid as well as a lubricator.
The normal operating pressure of pneumatic systems is very much lower than that
of hydraulic systems.
Output powers of pneumatic systems are considerably less than those of hydraulic
systems.
Accuracy of pneumatic actuators is poor at low velocities, whereas accuracy of
hydraulic actuators may be made satisfactory at all velocities.
Comparison Between Pneumatic Systems and Hydraulic Systems
In pneumatic systems, external leakage is permissible to a certain extent, but internal leakage
must be avoided. In hydraulic systems internal leakage is permissible to a certain extent, but
external leakage must be avoided.
Pneumatic systems are insensitive to temperature changes, in contrast to hydraulic systems in
which fluid friction due to viscosity depends greatly on temperature.
Pneumatic systems are fire- and explosion-proof, whereas hydraulic systems are not, unless
nonflammable liquid is used.
Pneumatic Nozzle-Flapper Amplifiers
Construction:
The power source for this amplifier is a supply of air at constant pressure.
The nozzle-flapper amplifier converts small changes in the position of the
flapper into large changes in the back pressure in the nozzle.
In Figure 4-5(a), pressurized air is fed through the orifice, and the air is ejected from
the nozzle towards the flapper.
To ensure proper functioning of the amplifier, the nozzle diameter must be larger than the
orifice diameter.
The diameter of the orifice is on the order of 0.25 mm and that of the nozzle is on the
order of 0.4 mm.
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The steep and almost linear part of the
curve is utilized in the actual operation
of the nozzle-flapper amplifier.
Pneumatic Nozzle-Flapper Amplifiers
Working:
The flapper is positioned against the nozzle opening.
The nozzle back pressure Pb is controlled by the nozzle-flapper distance X.
As the flapper approaches the nozzle, the opposition to the flow of air through the nozzle
increases, with the result that the nozzle back pressure Pb increases.
If the nozzle is completely closed by the flapper, the nozzle back pressure Pb becomes
equal to the supply pressure Ps.
If the flapper is moved away from the nozzle, so that the nozzle-flapper distance is wide
(on the order of 0.01 in.), then there is practically no restriction to flow, and the nozzle
back pressure Pb takes on a minimum value that depends on the nozzle-flapper device.
The lowest possible pressure will be the ambient pressure Pa.
The nozzle-flapper amplifier converts displacement into a pressure signal.
Relays
As the nozzle back pressure Pb increases, the
diaphragm valve moves downward. The opening
to the atmosphere decreases and the opening to
the pneumatic valve increases, thereby increasing
the control pressure Pc.
When the diaphragm valve closes the opening to
the atmosphere, the control pressure Pc, becomes
equal to the supply pressure Ps.
When the nozzle back pressure Pb decreases and
the diaphragm valve moves upward and shuts off
the air supply, the control pressure Pc, drops to
the ambient pressure Pa.
The total movement of the diaphragm valve is
very small.
In all positions of the valve, except at the position
to shut off the air supply, air continues to bleed
into the atmosphere, even after the equilibrium
condition is attained between the nozzle back
pressure and the control pressure bleed-type
relay.
Pneumatic P Controller
Bellows
Fig. 4.8 Schematic diagram of a force-distance type of pneumatic proportional controller
The amount of feedback can be regulated
by introducing a variable linkage
between the feedback bellows and the
flapper connecting point.
(b) flapper mounted on a fixed point; (c) flapper
mounted on a feedback bellow
Working of Pneumatic Proportional Controller
The input signal is the actuating error signal.
Increasing the actuating error signal moves the flapper to the left.
This move will, in turn, increase the nozzle back pressure, which in turn cause bellows F to expand and
move the flapper to the right, thus opening the nozzle.
Because of this feedback, the nozzle flapper displacement is very small, but the change in the control
pressure can be large.
It should be noted that proper operation of the controller requires that the feedback bellows move
the flapper less than that movement caused by the error signal alone.
If these two movements were equal, no control action would result.
When the actuating error is zero, ( e = 0), an equilibrium state exists with the nozzle-flapper distance
equal to 𝑋, the displacement of bellows equal to 𝑌, the nozzle back pressure equal to 𝑃𝑏 , and the
control pressure equal to 𝑃𝑐 .
The pneumatic controller shown in Figure 4-8(a) itself is a feedback system.
Since Pc, and e are proportional, the pneumatic controller shown in Figure 4-8(a) is a pneumatic
proportional controller.
Hydraulic Systems
Advantages of Hydraulic Systems
Hydraulic fluid acts as a lubricant, in addition to carrying away heat generated in the system to a
convenient heat exchanger.
Comparatively small sized hydraulic actuators can develop large forces or torques.
Hydraulic actuators have a higher speed of response with fast starts, stops, and speed reversals.
Availability of both linear and rotary actuators gives flexibility in design.
Because of low leakages in hydraulic actuators, speed drop when loads are applied is small.
Disadvantages of Hydraulic Systems
Hydraulic power is not readily available compared to electric power.
Cost of a hydraulic system may be higher than a comparable electrical system
performing a similar function.
Fire and explosion hazards exist unless fire-resistant fluids are used.
Because it is difficult to maintain a hydraulic system that is free from leaks, the system
tends to be messy.
Contaminated oil may cause failure in the proper functioning of a hydraulic system.
Hydraulic circuits have generally poor damping characteristics.
Hydraulic P Controller
Servomotor can be modified to a proportional controller by means of a feedback
link.
• The left-hand side of the pilot valve is joined
Pilot valve to the left-hand side of the power piston by a
link ABC.
• This link is a floating link
Power Piston
Figure 4-20
(a) Servomotor that acts as a proportional controller; (b) block diagram of the
servomotor.
Working
If input e moves the pilot valve to the right, port II will be uncovered and high-pressure
oil will flow through port I1 into the right-hand side of the power piston and force this
piston to the left.
The power piston, in moving to the left, will carry the feedback link ABC with it, thereby
moving the pilot valve to the left.
This action continues until the pilot piston again covers ports I and II.
The transfer function between y and e is a constant.
Thus, the hydraulic controller shown in Figure 4-20(a) acts as a proportional controller.
Kp can be adjusted by changing the lever ratio b/a.
Watch
What is a PID Controller?
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