On the design and control strategy of a digital proportional valve for high-water-based hydraulic systems

Abstract

The high-water-based directional valve serves as a key control element for actuating hydraulic supports in mining operations. However, conventional valve designs are increasingly inadequate in meeting the demands for high precision and digital control in modern support systems. To address this gap, the development of digital high-water-based proportional valves has become essential. Despite their potential, existing designs often suffer from excessive power consumption and structural complexity, limiting their practical application. In response, a digital high-water-based proportional valve suitable for high-flow conditions is proposed. This valve utilizes a hydraulic bridge circuit composed of high-speed switching valves for pilot control, effectively reducing the average power consumption during operation. Additionally, the hydraulic bridge directly controls the spool pressure to achieve proportional movement, minimizing intermediate stages between input and output and streamlining the overall structural design. Based on the completed main valve structure and control strategy, finite element simulations and system simulations of the proportional valve are conducted, verifying the valve’s functional feasibility. To simplify the experimental tuning process, a parameter self-tuning algorithm employing simulated annealing methodology is developed. Finally, prototype manufacturing and experimental validation of the proportional valve are performed. Under a maximum flow rate of 400 L/min, the valve achieves a response time of 150 ms and a hysteresis of 9.64% in spool displacement proportional control, with an average power consumption of 11.2 W. This research provides technical references for the design of high-water-based proportional valves, laying a foundation at the component level for the development of intelligence in fully mechanized coal face operations.

Graphical abstract

Keywords

hydraulic support / high-water-based proportional valve / high-speed switching valve / simulated annealing self-tuning algorithm

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