Design, construction and control of an electrohydraulic load simulator for testing hydraulic drives

Akova, Hayrettin Ulaş
In this thesis, an electro-hydraulic load simulator is designed, constructed, and controlled in order to carry out the stability and performance tests of newly developed hydraulic drive and control systems. It is an experimental loading system capable of applying the desired test loads onto the actuator of the hydraulic drive system under test in a laboratory environment. The primary aim of this study is to support the research activities related to the development of hydraulic drive and control systems so as to reduce their development period and to save the funds. A fluid power control system with a valve controlled linear actuator is designed as the load simulator. The selection of the hydraulic components of the system is presented in detail. A real-time control system is employed for controlling the electro-hydraulic load simulator. A test bench is designed and constructed in order to accommodate the actuators of the electro-hydraulic load simulator and the hydraulic drive system under test. A mathematical model of the system is developed and a simulation model is constructed by using MATLAB®/Simulink®. The model is validated by the results of open-loop tests. A combined feedforward and feedback force controller and a disturbance feedforward controller are designed by linearizing the validated model of the system around a critical operating point. The actuator position of the hydraulic drive system under test is measured with an incremental encoder and its velocity is estimated by a kinematic Kalman filter to be used in the disturbance feedforward controller. The controllers and the kinematic Kalman filter are implemented into a real-time control computer. The dynamic performance of the electro-hydraulic simulator developed is evaluated by performing a series of real time experiments and comparing their results with the model responses. In addition, the loading limits of the simulator are clearly demonstrated by both experimental tests and simulation results.


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Citation Formats
H. U. Akova, “Design, construction and control of an electrohydraulic load simulator for testing hydraulic drives,” M.S. - Master of Science, Middle East Technical University, 2014.