Operating-Point-Aware Parameterization of Pressure Control in Servo Hydraulic Drives

Operating-Point-Aware Parameterization of Pressure Control in Servo Hydraulic Drives | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Operating-Point-Aware Parameterization of Pressure Control in Servo Hydraulic Drives Selim Karaoglu, David Müller, Marius Hofmeister, Faras Brumand-Poor, and 1 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-9333712/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 6 You are reading this latest preprint version Abstract Hydraulic pressure control in servo-hydraulic drives strongly depends on the operating point, particularly on load pressure, which complicates reproducible PI controller tuning and leads to inconsistent closed-loop behavior. This study proposes a model-based parameterization methodology that systematically exploits manufacturer valve pressure-signal characteristics. The valve characteristic is transformed into a system-consistent pressure-signal curve by considering actuator geometry, internal leakage, and fluid properties. The reconstructed curve is used for inverse static feedforward compensation and, via local linearization, to derive operating-point-dependent first-order (PT1) pressure models. An Internal Model Control (IMC) framework maps the resulting model parameters to PI gains using a unified analytical rule. The approach establishes a continuous digital workflow from manufacturer datasheet information to controller parameterization and provides a basis for integration into Asset Administration Shell (AAS)-based engineering environments. Experimental validation on a mechanically coupled servo-hydraulic test bench demonstrates consistent pressure control performance across supply pressures of 40, 60 and 80 bar. In stationary operation, the method achieves tracking behavior close to system-identified optimal tuning while increasing feedforward dominance compared to direct manufacturer-based parametrization. Under dynamic motion conditions, robust performance is maintained despite higher feedback demand at elevated load levels. The results confirm scalable and reproducible pressure control across a wide operating range without manual retuning. Hydraulic pressure control Servo valves Operating-point-dependent modeling Controller parameterization Internal Model Control Valve characteristics Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Under Review Version 1 posted Reviewers agreed at journal 19 May, 2026 Reviewers invited by journal 21 Apr, 2026 Editor invited by journal 19 Apr, 2026 Editor assigned by journal 17 Apr, 2026 Submission checks completed at journal 14 Apr, 2026 First submitted to journal 14 Apr, 2026 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-9333712","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":624977849,"identity":"8115b7ed-7c00-4662-99d3-1d93b8cccb13","order_by":0,"name":"Selim Karaoglu","email":"data:image/png;base64,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","orcid":"","institution":"RWTH Aachen University","correspondingAuthor":true,"prefix":"","firstName":"Selim","middleName":"","lastName":"Karaoglu","suffix":""},{"id":624977850,"identity":"146b4295-6112-4016-8ef7-05eef688ea86","order_by":1,"name":"David Müller","email":"","orcid":"","institution":"RWTH Aachen University","correspondingAuthor":false,"prefix":"","firstName":"David","middleName":"","lastName":"Müller","suffix":""},{"id":624977851,"identity":"8ba40e91-dccb-4cbf-9f83-5033659fba38","order_by":2,"name":"Marius Hofmeister","email":"","orcid":"","institution":"RWTH Aachen University","correspondingAuthor":false,"prefix":"","firstName":"Marius","middleName":"","lastName":"Hofmeister","suffix":""},{"id":624977852,"identity":"b9f33b88-3bde-4505-a21b-d27b7a2daed6","order_by":3,"name":"Faras Brumand-Poor","email":"","orcid":"","institution":"RWTH Aachen University","correspondingAuthor":false,"prefix":"","firstName":"Faras","middleName":"","lastName":"Brumand-Poor","suffix":""},{"id":624977853,"identity":"459f8c86-698c-4dc5-b5f0-42fdf95f14ac","order_by":4,"name":"Katharina Schmitz","email":"","orcid":"","institution":"RWTH Aachen University","correspondingAuthor":false,"prefix":"","firstName":"Katharina","middleName":"","lastName":"Schmitz","suffix":""}],"badges":[],"createdAt":"2026-04-06 12:08:42","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-9333712/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-9333712/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":107485471,"identity":"5f65cac8-cf00-4819-abbe-7366170fc738","added_by":"auto","created_at":"2026-04-22 02:35:01","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":7580066,"visible":true,"origin":"","legend":"","description":"","filename":"OperatingPointAwareParameterizationofPressureControlinServoHydraulicDrives.pdf","url":"https://assets-eu.researchsquare.com/files/rs-9333712/v1_covered_23f8ed17-0196-463b-bc7f-2417fe01beba.pdf"}],"financialInterests":"No competing interests reported.","formattedTitle":"Operating-Point-Aware Parameterization of Pressure Control in Servo Hydraulic Drives","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":true,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"discover-mechanical-engineering","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"discmecheng","sideBox":"Learn more about [Discover Mechanical Engineering](https://www.springer.com/journal/44245)","snPcode":"44245","submissionUrl":"https://submission.nature.com/new-submission/44245/3","title":"Discover Mechanical Engineering","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"stoa","reportingPortfolio":"Discover Series","inReviewEnabled":true,"inReviewRevisionsEnabled":true},"keywords":"Hydraulic pressure control, Servo valves, Operating-point-dependent modeling, Controller parameterization, Internal Model Control, Valve characteristics","lastPublishedDoi":"10.21203/rs.3.rs-9333712/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-9333712/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"Hydraulic pressure control in servo-hydraulic drives strongly depends on the operating point, particularly on load pressure, which complicates reproducible PI controller tuning and leads to inconsistent closed-loop behavior. This study proposes a model-based parameterization methodology that systematically exploits manufacturer valve pressure-signal characteristics. The valve characteristic is transformed into a system-consistent pressure-signal curve by considering actuator geometry, internal leakage, and fluid properties. The reconstructed curve is used for inverse static feedforward compensation and, via local linearization, to derive operating-point-dependent first-order (PT1) pressure models. An Internal Model Control (IMC) framework maps the resulting model parameters to PI gains using a unified analytical rule. The approach establishes a continuous digital workflow from manufacturer datasheet information to controller parameterization and provides a basis for integration into Asset Administration Shell (AAS)-based engineering environments. Experimental validation on a mechanically coupled servo-hydraulic test bench demonstrates consistent pressure control performance across supply pressures of 40, 60 and 80 bar. In stationary operation, the method achieves tracking behavior close to system-identified optimal tuning while increasing feedforward dominance compared to direct manufacturer-based parametrization. Under dynamic motion conditions, robust performance is maintained despite higher feedback demand at elevated load levels. The results confirm scalable and reproducible pressure control across a wide operating range without manual retuning.","manuscriptTitle":"Operating-Point-Aware Parameterization of Pressure Control in Servo Hydraulic Drives","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2026-04-20 01:40:32","doi":"10.21203/rs.3.rs-9333712/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"reviewerAgreed","content":"292406727964251817286169513169013802773","date":"2026-05-19T06:51:12+00:00","index":"hide","fulltext":""},{"type":"reviewersInvited","content":"","date":"2026-04-21T14:00:23+00:00","index":"","fulltext":""},{"type":"editorInvited","content":"","date":"2026-04-20T03:04:01+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2026-04-17T12:25:45+00:00","index":"","fulltext":""},{"type":"checksComplete","content":"","date":"2026-04-14T07:55:16+00:00","index":"","fulltext":""},{"type":"submitted","content":"Discover Mechanical Engineering","date":"2026-04-14T07:39:59+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"discover-mechanical-engineering","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"discmecheng","sideBox":"Learn more about [Discover Mechanical Engineering](https://www.springer.com/journal/44245)","snPcode":"44245","submissionUrl":"https://submission.nature.com/new-submission/44245/3","title":"Discover Mechanical Engineering","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"stoa","reportingPortfolio":"Discover Series","inReviewEnabled":true,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"c54d6c90-7af9-4bfd-9ae3-50851d1656f1","owner":[],"postedDate":"April 20th, 2026","published":true,"recentEditorialEvents":[{"type":"reviewerAgreed","content":"292406727964251817286169513169013802773","date":"2026-05-19T06:51:12+00:00","index":64,"fulltext":""}],"rejectedJournal":[],"revision":"","amendment":"","status":"under-review","subjectAreas":[],"tags":[],"updatedAt":"2026-04-21T14:08:47+00:00","versionOfRecord":[],"versionCreatedAt":"2026-04-20 01:40:32","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-9333712","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-9333712","identity":"rs-9333712","version":["v1"]},"buildId":"XKTyCvWXoU3ODBz1xrDgd","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}