Servovalve, Hydraulic - Equations

The nonlinear equations for a flapper nozzle servovalve are developed in this section. A
simplified model is presented at the end of the section. For references purposes, the full
servoactuator is shown in Figure 1. For a description of operation, see Servovalve, Hydraulic –
Description. The equations are developed for each stage.

Figure 1 Flapper Nozzle Servoactuator

Flapper Nozzle System

The flapper nozzle system consists of torque motor and flapper nozzle. Figure 2 shows the
flapper nozzle system from Figure 1, which additional parameters identified.

Figure 2 Flapper Nozzle System

The flapper is driven by a electro-magnetic torque motor. Input to the torque motor is an applied
current from a controller. The torque motor has inductance and resistance in the windings,
leading the following equation for current buildup torque motor
L
tm I& + I = k u (1)
R a
tm
where
Ltm inductance of the torque motor
Rtm resistance of the torque motor
ka current gain amplifier of the controller
u current from electronic controller
i current seen by the armature

For small armature rotations, the torque can be assumed to be linear with current, so that

T = βI (2)

where β is the gain of the torque motor in units of in-lb/ma. A typical value is around 0.025 in-
lb/ma. Equation (1) and (2) describe the dynamics associated with creating a torque on the
flapper. For armatures with multiple windings, such as i1 and i2 shown in Figure 2, equations (1)
and (2) may be applied to each winding and combined to yield the total armature torque.
The next step is to compute flapper position at the nozzle. For small rotations of the flapper,
variation of gap distance due to armature rotation is given by (see Figure 2).
l
x = ax (3)
g l f
f

la
xg
θ

lf

xf

Figure 3 Flapper Rotation

where
xg armature tip distance
lf flapper length
la armature length
xf gap distance (typical value at neutral = 0.0015 in)

The flapper generally rotates over very small angles (~ 0.01 rad), so equation (4) is valid. The
first stage (torque motor stage) of a servo valve is essentially a mechanical position control
system. The input is current and the output is flapper position. The equations of motion for the
flapper can be written using Newton’s 2nd law,

Jθ&& = ∑ F (4)
With xf = lf θ,
J D k
a &&
x + x& + x =T −T −T
l f l f l f a flow fb spring
f f f

or
J (5)
a &&
x + σ x& + k x = T − T −T
l f f f a f a flow fb spring
f

where
Ta applied torque from torque motor
Ja inertia of the flapper armature
 σf viscous friction coefficient of the flapper
ka stiffness of the flexure tube that connects the flapper to the housing
Tflow torque due to flow forces
Tfb spring feedback spring torque (zero if feedback spring is not utilized)

A theoretical equation for the flow force acting on the flapper is

16α  2 
T
flow
π
= d 2l 1 +
4 n f
dn x 2 + x 2   P − P
d2  f 0 f   n1 ( n2 ) (6)
 n 

(
+8π l α 2 x x P − P − 2P
f dn f 0 f n1 n2 n3 )
where
Pn1 nozzle inlet pressure for nozzle 1
Pn2 nozzle inlet pressure for nozzle 2
Pn3 pressure downstream of nozzle 1 and nozzle 2
αdn discharge coefficient for the nozzle
dn diameter of the nozzle

If a position feedback spring exists from the spool to the flapper, the feedback spring torque
acting on the flapper can be computed using

l +l 
 f fb (7)
T =k x +x 
fbspring fb  l f s
 f 

where kfb is the spring rate for the feedback wire (cantilever beam). If the spool position feedback
is electrical only or no feedback is used, Tfb spring = 0.
Applying the following general pressure derivative equation

P& =
β
V
(
∑Q − ∑Q
in out
β
− V&
V
) (8)
0 0
to the spool and nozzle volumes yields the pressure derivative equations

P& =
n1 V
β′
(
Q − Q − A x&
01 n1 s s )
n1
P& =
n2 V
β′
02 n2(
Q − Q + A x&
s s ) (9)
n2
P& =
n3 V
β′
Q +Q −Q
n1 n2 ( n3 )
n3
where
 β’ effective fluid bulk modulus
Vni chamber volumes
As spool side area
x& spool velocity
s
The flows through the inlet orifices (or nozzles) are

Q =A α
01
2
P −P
0 dn ρ s n1 ( )
(10)

ρ ( s n2 )
2
Q =A α P −P
02 0 dn

where A0 is the orifice area of the inlet nozzle, ρ is the density, and αdn is the discharge coefficient
for the nozzle. For turbulent flow through the flapper nozzles

Q =α π d x + x 
n1 dn n  f 0 f
2
(P − Pn3 )
ρ n1
(11)

ρ ( n2 n3 )
2
Q =α π d x − x  P −P
n2 dn n  f 0 f

where
Pni i = 1, 2, 3 nozzle pressures
xf flapper displacement
xf0 flapper displacement in neutral position
dn nozzle diameter
αdn discharge coefficient of the nozzle (turbulent flow)
ρ fluid density

The flow equations, equations (9) and (10), are valid only if flapper flow area is proportional to
flapper position, i.e., for

πd2
x ⋅ π d << n
n 4
Lastly, for the outlet orifice

Q =A α
n3
2
P −P
n3 dn ρ n3 rtn ( ) (12)

where An3 is the outlet orifice area and Prtn is the return line pressure.

Pilot Spool Dynamics

The pilot spool dynamics are derived by applying Newton’s 2nd Law, F = ma, to the pilot spool.
Figure 4 shows the pilot spool with important parameters defined.

Figure 4 Servovalve Schematic and Parameters

Referring to Figure 4, Newton’s law for the spool yields

T
&&
s s
&
f s ()
m x +F x +k x =A P −P
s s
−
s n1 n2 l + l (
fb
−F
ax ) (13)
f fb
where

F = 2α cosθ
ax dn (
 s1 s e )
A P − P − A P − P
s2 e rtn(+A P −P
s3 r rtn
−A)
s4 s( r  )
P − P  (14) ( )
and
αdn turbulent nozzle discharge coefficient
ms mass of the pilot spool
Ff velocity dependent friction forces
lfb length of the feedback spring
Fax axial force on the spool due to flow
Asi spool port opening areas
ks overall spring constant
θ jet angle, assumed constant at θ =69 deg
Assuming zero lapping and zero leakage, the servovalve flows are given by following equations,
with the signum function defined as

x x≥0
sg(x) =  (15)
0 x<0

e ( ) ( ) Ps − Pe
Q = c sg x sign P − P
v1 s s e

−c sg (−x )sign (P − P ) P − P
v2 s e rtn e rtn
(16)

r ( ) ( ) Ps − Pr
Q = c sg −x sign P − P
v3 s s r

−c sg (x )sign (P − P ) P − P
v4 s r rtn r rtn
For underlapped valves, which provide a faster response, with higher leakage and decreased
control accuracy, the flow equations are

e ( ) ( ) Ps − Pe
Q = c sg x + x sign P − P
v1 u1 s s e

−c sg (x − x )sign (P − P ) P − P
v2 u2 s e rtn e rtn
(17)

r (u3 s ) ( ) Ps − Pr
Q = c sg x − x sign P − P
v3 s r

−c sg (x + x )sign (P − P ) P − P
v4 u4 s r rtn r rtn

where xui ≥ 0, are the amount of underlap.

For overlapped valves, which introduce a deadband (time delay), the flow equations are

e ( o1 s ) ( ) Ps − Pe
Q = c sg −x + x sign P − P
v1 s e

−c sg (−x − x )sign (P − P ) P − P
v2 o2 s e rtn e rtn
(18)

r ( o3 s ) ( ) Ps − Pr
Q = c sg −x − x sign P − P
v3 s r

−c sg (−x + x )sign (P − P ) P − P
v4 o4 s r rtn r rtn
where xoi ≥ 0, are the amount of overlap.

If the position of the pilot spool xs is fed back to the pilot stage by an electrical feedback loop as
shown in Figure 5, the feedback (both position and velocity feedback) is of the form

u=k
pm  v (
u − 1 + k s x 
dm s ) (19)

where
kpm proportional gain
kdm velocity feedback gain
uv current from electronic controller
s Laplace variable (1st order derivative in time domain)

In some applications, electrical spool position is fed back into the torque motor command (in the
controller) through an LVDT mounted on the spool. Figure 5 shows a Linear Variable Differential
Transducer (LVDT) connect to the pilot spool. In this case, equation (1) is written as

( )
L
m I& + I = k u − 1 + k s x  (20)
R pm  v dm s 
m
Velocity feedback is used to improve system damping and bandwidth. For further details, see
Servovalve, Hydraulic – Position Control Loop).

Figure 5 Servo Schematic with Linear Variable Differential Transducer (LVDT)

Using the above equations, a servo can be analyzed either as a complete system or as a
subsystem using the appropriate equations.

Actuator
The dynamic equations for the actuator portion of the servoactuator can be found in Actuator,
Hydraulic – Equations. The dynamic equations for the actuator include 2 pressure derivative
equations for P&A and P&B plus the 2nd order equation for actuator piston motion.

Simulation Models
Simulation models, either servoactuator or servo-subsystem, can be evaluated in 3 methods via

1. Non-linear simulation analysis

2. Non-linear analysis methods
3. Linearized model analysis

A discussion of each method follows.

Non-Linear Simulation Analysis

A non-linear simulation block diagram is shown below.

uv (current input)
Tflapper Torque
Motor
(β)
Eqn (2) Position Feedback (if used)

Pn1 QE Actuator
Ps Actuator
Flapper Pilot Spool Position
Chamber
Nozzle Position
Flow Eqns
PE Actuator
Prtn Equations Pn2 Equation PR Model
xs (17), (18)
(7) (12)
or (19)
QR

Ps Prtn

Figure 6 Complete Nonlinear Simulation Diagram

Using appropriate equations for each block, the servo valve can be simulated under a variety of
conditions and performance verified. This model can also be included in a larger system model,
with included piping, actuators, etc. to validate system level performance.
When conducting system level investigations, it is possible to simplify the above block diagram.
A simplified model is generally more convenient to use (see Figure 7).
 QE
1 Actuator
i uv PE
 1 2 2 Dv  Chamber Actuator
 s + s + 1 Flows Eqns PR Model
ω2 ω 
 v v  (22), (23)
QR
Flapper Nozzle &
Spool Dynamics
Ps Prtn

Figure 7 Simplified Nonlinear Simulation Diagram (Servovalve Only)

In this simplified representation, the flapper nozzle and spool dynamics are represented by a 2nd
order transfer function. This model generally is a reasonable simplification for modeling a
servovalve since the servo dynamics are much faster than the actuator dynamics. Values for the
servo natural frequency, ωv, and damping, Dv, are found in the manufacturers’ catalogs, which is
another reason why the simplified model is advantageous.

As discussed in Servo, Hydraulic – Equations, flows can also be computed using manufacturer’s
catalog data. The servo valve gain, kv, provides servo port flow area as a function of input
current, uv. Using available catalog data, for a four way valve,

Q 1
k = N (21)
v ∆p /2 u
N v, max

where

QN rated flow at rated pressure and max input current

∆pN pressure drop at rated flow and max input current
uv,max max rated current

Actuator flows, QE and QR are computed using the same equations, with the flow areas computed
using kv, i.e., for uv > 0

Q =k u
A
1
v v ρ 1 A ( ) ( )
P − P sign P − P
1 A
(22)

ρ ( B rtn ) ( B rtn )
1
Q = −k u P − P sign P − P
B v v

and for uv < 0

 Q = −k u
A
1
P − P sign P − P
v v ρ rtn A rtn A ( )
(23)
Q = −k u
B v v ρ 1 B
1
P − P sign P − P
1 B ( )
where P1 is the inlet pressure to the servo valve and all other variables are as defined earlier.
These are the equations to use in the simplified model for zero lapped servovalves. Appropriate
modifications to these equations are required for underlapped and overlapped valves [Ref:
equations (18) & (19)].

Nonlinear State (Analysis) Model

Nonlinear state models have the general form

& = f [x(t)]+ g [x(t)] u(t)

x(t)
(24)
y(t) = h [x(t)]
where
x(t) vector of state variables for the system (integrations)
u(t) vector of input variables for the system
y(t) vector of output variables for the system
f,g,h nonlinear vector functions

For a 2 stage servovalve, x, u and y are the vectors below

8 States :

x(t ) =  I , x , x& , P , P , P , x , x& 

 f f n1 n 2 n 3 s s 

3 Inputs :
u (t ) =  u (t ), P , P 
 e r

3 Outputs :
y(t ) =  x , Q , Q 
 s e ri 

The nonlinear state equations are

  I&   f1   Rtm 
     k 
 x& f   f2   tm a 
L
     
x 
 &&  f3 
f  0  u 
     0 
 P&n1   f4   v
  P 
&  = f  +  0  (25)
 Pn2   5  e
 0  P 
&  f     r
 Pn3   6  0 
 x&  f   0 
 s   7  
 &&
x  f   0 
 s   8 
where
R
f =− mI
1 L
m
f = x&
2 f

l  
f =
f  D
3 J  l f l
k
− x& − x + β I +  k + k x 2  p − p
f  1 3 f  n1 n2 ( )

a f f 
β 
f = e A α
4 V

2
p −p
0 dn ρ s n1 (
− α πd x
dn n f ) p −p +A
n1 n3
x&

s, pi v, pi 

n1
β 
f = e A α
5 V

2
p −p
0 dn ρ s n2 (
+ α πd x
dn n f ) p −p −A
n2 n3
x&

s, pi v, pi 

n2
β 
f = e α π d x
6 V dn n f
p − p − α πd x
n1 n3 dn n f
p −p −A α
n2 n3
2
p −p
3 dn ρ n 3

rtn  ( )
n2  

f = x&
7 v, pi

f =
8 m
1 
( )   o 
 Ass, pi PN1 − PN 2 − F f  x&v, pi  − 2α d cos 69 Term1
s, m  n 

 
Term1 =  A  P − P  − A P − P  + A P − P  − A P − P
 s1  s A, pi  s2  A, pi rtn  s3  B, pi rtn  s4  s B, pi  
The output equation, y = h(x) is

 
x
 xs   s 
   

  
() ( ) ( ) (
Qe  =  cv1sg xs sign Ps − Pe Ps − Pe − cv2 sg −xs sign Pe − Prtn ) P −P
e

rtn 
Qr  
( ) ( ) () ( )

 cv3sg −xs sign Ps − Pr Ps − Pr − cv4 sg xs sign Pr − Prtn P −P 
r rtn 

(26)

Linear Model
Equations for a linear model and a simulation block diagram are developed in Servovalve,
Hydraulic – Linear Model. Examining equations in this section, servovalve equations are
inherently nonlinear. The nonlinearities result from hysteresis, friction and orifice flow.
Linear models are developed from the nonlinear equations by linearizing around a chosen
operating point (often near the null position, but any operating condition can be chosen). The
equations will only be accurate over a small range of operation from the linearized operating
point. Significant errors will result if the linear model is used for the full operating range of the
servovalve.
The main purpose for creating linear models is to evaluate the frequency response of the valve
and to compute gain and phase margins for closed loop position controls systems that use a
servoactuator. The only method to obtain gain and phase margins is through a linear model.
Gain and phase margins are normally a specification requirement for closed loop control systems.