DIGITAL SERVOVALVES The smart approach to electrohydraulic motion control 3rd Workshop on Innovative Engineering for Fluid Power 1 Digital Servovalves AGENDA − Introduction - MOOG − Electrohydraulic motion control − Modern Automation − Digital Servovalve − Applications Abstract The integration of powerfull microprocessor based electronics in the servovalves is allowing new and flexible motion control architectures. Smart “automation nodes” coupled with high speed communication are revolucionizing the concept of motion control automation. In this presentation we are going to explore the history and reasons behind the digital valve development, the technology’s state-of-the-art and application examples. 2 Digital Servovalves AGENDA − Introduction - MOOG − Electrohydraulic motion control − Modern Automation − Digital Servovalve − Applications 3 Digital Servovalves COMPANY PROFILE • Established in 1951, by Bill Moog • Focus in high performance motion control solutions for industrial, military and aerospace applications. • Sales (FY16) = US$ 2,6 Billions • 10.700 employees • Headquarter: Buffalo, NY 4 Digital Servovalves MOOG HEADQUARTERS (Buffalo-NY) HR c Aircraft Industrial Corporate Offices Space & Defense 5 5 Digital Servovalves GLOBAL PRESENCE Asia Pacific Japan Philippines China India Korea Australia Singapore Americas USA Canada Europe Brazil Germany Italy Luxembourg Russia United Kingdom Spain France Turkey The Netherlands South Africa Ireland 6 Digital Servovalves 4 GROUPS MOOG INC. US$ 2.6 BILLIONS FY16 SPACE AND AIRCRAFT INDUSTRIAL COMPONENTS DEFENSE GROUP GROUP GROUP GROUP US$ 1,2 B US$ 591 M US$ 545 M US$ 395 M 22% 44% % Revenue 20% 14% 7 7 Digital Servovalves 4 GROUPS Space and Aircraft Industrial Components Defense Group Group Group Group primary and high performance Slip rings, small missiles/ launchers secondary flight motion control for motors & actuators, trajectory control, controls, engine industrial fiber optics antenas and solar controls applications, test interfaces, air panels positioning, and simulation cooling solutions, satelites atitude infusion pumps control, infusion pumps 8 Digital Servovalves INDUSTRIAL GROUP Moog Inc. Space & Aircraft Industrial Components Defense Group Group Group Group Brazil Italy Sweden France Korea Singapore Australia Germany China Spain South Africa The Neederlands Russia Hong Kong 9 9 Digital Servovalves MOOG do Brasil Controles Ltda Plant 1: Rua Prof Campos Oliveira, 338 Plant 2: Rua Agostinho Togneri, 457 São Paulo SP phone +55 (11) 3572-0400 www.moog.com.br 10 Digital Servovalves INDUSTRIAL GROUP - PRODUCTS 11 Digital Servovalves INDUSTRIAL GROUP - MARKETS ENERGY SIMULATION TEST Wind Gas, oil, hydro Aero Automotive HEAVY INDUSTRY METAL FORMING OIL & GAS PLASTICS SERVICES Steel mills Presses Repairs 12 12 Digital Servovalves AGENDA − Introduction to MOOG − Electrohydraulic motion control − Modern Automation − Digital Servovalve − Applications 13 Digital Servovalves SERVOCONTROL • Closed loop motion control • Control of: position, velocity, acceleration, force, pressure LINEAR ROTARY position 푥 angular position θ 푑푥 푑휃 velocity 푥 = = 푣 velocity 휃 = = ω 푑푡 푑푡 푑푣 푑휔 acceleration 푥 = = 푎 acceleration 휃 = = α 푑푡 푑푡 force 퐹 torque T pressure 푝 • Tecnologies: ELECTROHYDRAULIC, electromechanical, electrohydrostatic 14 Digital Servovalves ELECTRO-HYDRAULIC MOTION CONTROL V∙I p∙Q p∙Q F∙v Elements: pump, valve, hydraulic cylinder. 푷풐풘풆풓 풊풔 풕풓풂풏풔풎풊풕풆풅 풃풚 풕풉풆 풇풍풖풊풅 푷 = 푸 ∙ 풑 = (풇풍풐풘 풙 풑풓풆풔풔풖풓풆) 15 Digital Servovalves ELECTRO-HYDRAULIC MOTION CONTROL Example: position control Actuator position 푥 A A position ERROR Q set point Servovalve Ksa + SERVO Kq AMPLIFIER - P R Kf FEEDBACK TRANSDUCER volts mm flow velocity position Disturbances Disturbances + + + position + 1 + K K 푣(푡) set point sa q A 푥 - 푄 푥 Kf 16 Digital Servovalves ELECTRO-HYDRAULIC MOTION CONTROL SERVOVALVES MFB = Mechanical Feedback nozzle–flapper pilot EFB = Electrical Feedback ServoJet pilot EFB = Electrical Feedback DDV pilot 17 Digital Servovalves ELECTRO-HYDRAULIC MOTION CONTROL Analog Servovalve Digital Servovalve 18 Digital Servovalves AGENDA − Introduction to MOOG − Electrohydraulic motion control − Modern Automation − Digital Servovalve − Applications 19 Digital Servovalves AUTOMATION TECHNOLOGY LEVEL DEVICES COMMUNICATION volume Cloud + Corporate Admin &Planning Ethernet WAN D Production Servers & PCs A Ethernet LAN T Process Control SCADA ControlNet A Profibus-PA PLCs, NCs, Word FIP CANopen Machine Control Motion control Foundation Profibus-DP EtherCAT + Transducers/ “Sensing” Actuators PowerLink VARAN ProfiNet speed Sercos (throughput) SCADA = Supervisory Control and Data Acquisition 20 Digital Servovalves TRADITIONAL AUTOMATION ARCHITECTURE CENTRALIZED CONTROL #2 #1 #3 #4 #6 MMI #8 #5 #7 #9 #12 #13 #10 #15 #11 #14 #n Inputs and Outputs 4a 20mA, +/- 10volts, +/-10mA , on/off 21 Digital Servovalves MODERN (FACTORY 4.0) AUTOMATION ARCHITECTURE DISTRIBUTED CONTROL #11 #2 User/operator #4 Interface #3 “Supervisor” #6 #7 #8 FIELDBUS #9 #5 #11 #10 #13 #15 #12 #14 #n Devices , Nodes, Participants Digital Communication + Stand alone Operation + Configuration + Remote Diagnostics 22 Digital Servovalves FIELDBUS - Definition by IEC 61158-2 Digital data communications for measurement and control for use in industrial control systems OSI 7 layers model 7 – Application Layer IEC 61158 standard consists of the following parts: 6 – Presentation Layer Part 1: Overview and guidance for the IEC 61158 series Part 2: Physical Layer specification and service definition 5 – Session Layer Part 3: Data Link Service definition 4 – Transport Layer Part 4: Data Link Protocol specification Part 5: Application Layer Service definition 3 – Network Layer Part 6: Application Layer Protocol specification 2 – Data Link Layer 1 – Physical Layer OPEN PROTOCOL = when used layers are clearly specified, documented and made available to interested users = interoperability & compatibility Only layers 1, 2 and 7 are specified for FIELDBUSSES! • IEC (International Electrotechnical Commission) is a worldwide organization for standardization that promotes international co-operation on all questions concerning standardization in the electrical and electronic fields. • OSI (Open Systems Interconnection) defined by ISO Standards 23 23 Digital Servovalves FIELDBUS - make your choice! ;>) BSAP - Bristol Babcock Inc EGD - GE Fanuc DF-1 Fieldbus FOUNDATION CC-Link FINS - Omron CIP -Common Industrial Protocol - ODVA GE SRTP - GE Fanuc PLCs CAN -Controller Area Network - Bosch Host Link - Omron CAN open Mechatrolink - Yaskawa ControlNet - Allen-Bradley MelsecNet/10 - Mitsubishi Electric DeviceNet - Allen-Bradley Optomux - Opto 22 Interbus - Phoenix Contact PieP - Open Fieldbus Protocol HART Protocol (run in 4-20mA lines) Profibus - Siemens Modbus RTU - Schneider Profibus-DP Modbus NET Profibus-PA Modbus TCP SERCOS Modbus Plus Sinec H1 - Siemens Modbus PEMEX SynqNet - Danaher * Supported by MOOG 24 Digital Servovalves FIELDBUS - Ethernet-based, real time communication EtherCAT - Beckhoff Automation EtherNet/IP - ODVA Ethernet Powerlink - B&R PROFINET - Siemens SafetyNET p – Pilz GmbH SERCOS III - Sercos International TTEthernet -TTTech Computertechnik AG VARAN - VNO (Varan-bus Nutzerorganisation) RAPIEnet - Korea CANopen 1 Mbit/sec Profibus DP 12 Mbit/sec * Supported by MOOG EtherCAT, PowerLink, Varan 100 Mbit/sec 25 Digital Servovalves FIELDBUS + / - PLUS: • Direct communication between the PLC (Fieldbus-Master) and actuators/transducers lower cost wiring and smaller electrical cabinet reduced number of discrete I/Os • Digital command and feedback signals no noise, no loss • Remote monitoring, parametrization, diagnostics, troubleshooting • Direct communication between slave devices is possible in some fieldbusses MINUS: • Real time communication capability is limited depending on the fieldbus speed and the number of connected devices. • Devices are more expensive (must have built-in fieldbus interface) • Implementation requires skilled workforce 26 Digital Servovalves AGENDA − Introduction to MOOG − Electrohydraulic motion control − Modern Automation − Digital Servovalve − Applications 27 Digital Servovalves HISTORY • 1992: checking the possibility of controlling a servovalve with digital electronics 1 1 1 • 1995: industrial controller (eurocard format) installed in a servovalve with analogue spool control, simple CAN interface. • 1998: embedded hardware/software, basic CANopen and VDMA standard functionalities, mixed analogue/digital spool position control. • 2000: DCV (Digital Control Valve): 2 boards design electronics, full CANopen, full VDMA, full digital valve control , MoVaCo (Configuration Software Tool) Verband Deutscher Maschinen- und Anlagenbau Mechanical Engineering Industry Association 28 Digital Servovalves HISTORY • 2003: digital pQ valve (pressure + flow control) • 2005: modular design (3 boards), Profibus, aditional analog and digital inputs, digital RKP pumps • 2007: ACV (Axis Control Valve): closed loop with external transducers • 2009: EtherCAT • 2011: improved electronics, powerfull microprocessors • 2012: new configuration software tool ( MoVaPuCo), VARAN • 2014: explosion proof versions, new models • 2016: PowerLink 29 Digital Servovalves A LARGE FAMILY OF DIGITAL VALVES Models 30 Digital Servovalves DCV - DIGITAL CONTROL VALVE Functionality & Interfaces DCV-Q : Flow Control DCV-pQ : Flow & Pressure Control Analog Command Analog Command + Integrated Pressure Transducer DCV-Q : Flow Control DCV-pQ : Flow & Pressure Control Digital