NEW STRATEGY FOR DESIGN AND FABRICATING OF A GRAIN SORTING SYSTEM USING HIGH-SPEED PIEZOELECTRIC VALVES

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1 NEW STRATEGY FOR DESIGN AND FABRICATING OF A GRAIN SORTING SYSTEM USING HIGH-SPEED PIEZOELECTRIC VALVES So-Nam Yun*, Hwang-Hun Jeong**, Dong-Gun Kim**, Eun-A Jeong** and Hong-Hee Kim*** * Department of Energy Systems, Korea Institute of Machinery and Materials Shinseongno 104, Yuseong-gu, Daejeon, Korea ( ysn688@kimm.re.kr) ** Department of Energy Systems, Korea Institute of Machinery and Materials Shinseongno 104, Yuseong-gu, Daejeon, Korea ( hhjeong@kimm.re.kr) *** Technology Institute, Kyungwon Ferrite Ind. Co. Ltd., 2-na-205, Jeongwang-dong, Shiheung, Kyunggi, Korea ABSTRACT The purpose of this paper is to develop a new type pneumatic valve which has a multilayered bender type piezo actuator and is used for a grain sorting system. In this study, a new type high-speed pneumatic valve with a piezo actuator for a grain sorting system was analyzed, designed and fabricated, and performances of the fabricated pneumatic valve were evaluated. Finally, an endurance test was conducted, and it was confirmed that the new type piezo pneumatic valve is possible to use to the ejector for grain sorting system. KEY WORDS Key words, PZT valve, Piezoelectric valve, Piezo actuator, Grain sorting system, Color sorter INTRODUCTION Figure 1 shows the structure and an operating principal of the grain sorting system. Grains in the Hopper run down through the Feeder and the Chute. Foreign bodies, which are found by the lamp and the image sensor, are removed by an air ejector. In this case, not only the distinction capability of foreign bodies but also the fine removing ability is very important. The response characteristics of an air ejector are also one of important design parameters. An air ejector consists of an air gun with a small volume and a pneumatic valve. So they want the high-speed pneumatic valve. Many kinds of methods for overcoming the above-mentioned problems such as response characteristics and low power consumption one have been suggested. Figure 2 shows the pressure lag characteristics by input voltage wave to the object pneumatic valve, and these characteristics are differ from the used solenoid valve such as Solenoid_1 and Solenoid_2. If we use the Solenoid_1 and the Solenoid_2 of figure 2, we can t help the precise control to remove the foreign bodies in grains because the lag response characteristics. Figure 3 shows the schematic diagram with cross sectional view of a solenoid valve for a grain sorting system which had been studied by Z. Xiang. The valve was designed as a 2/2-way electro-magnetic solenoid operated on-off valve, and this consists of four major

2 bodies and armature and stator with a coil. To realize the long lifecycle requirement, an air pressure return structure valve was adopted and there is no spring for avoiding the spring fatigue problem in the traditional spring return valve. The other method is to make one stationary core with two parallel coils. This was suggested by Tomohiko Katagiri, and it was known to have some characteristics like very short displacement and adoption of a plate type plunger for high-speed performance. The purpose of this paper is to develop a new type pneumatic valve which has a multilayered bender type piezo actuator and is used for a grain sorting system. In this study, a new type high-speed pneumatic valve with a piezo actuator for a grain sorting system is analyzed, designed and fabricated, and performances of the fabricated pneumatic valve are evaluated. Finally, an endurance test is conducted.. Figure 3 Schematic diagram with cross sectional view of a solenoid valve for a grain sorting system (from Z. Xiang) PIEZOELECTRIC ACTUATOR DESIGN AND MANUFACTURING Figure 4 shows the structure of a designed and manufactured piezoelectric actuator. Dimensions of the manufactured actuator are 50L х 10W х 0.80t ( mm3 ) and dimensions of ceramics are 38L х 10W х 0.40t. Ceramic sheet thickness is 40 μm and number of layers is 9. And the capacitance of the manufactured piezoelectric is 1.26 μf. Figure 1 Structure and operating principal of a grain sorting system (1 chute and 1 ejector with a PZT valve) Figure 2 Input voltage and output pressure wave a pneumatic valve for a grain sorting system a) Exploded view

3 b) Fabricated piezoelectric actuator c) Assembled actuator with CFRP Figure 4 Manufactured piezoelectric actuator Figure 5 and figure 6 show the photo view and the operating principal of the manufactured piezoelectric actuator, respectably. To realize the long lifecycle requirement like Z. Xiang s study, an air pressure stops the flow out orifice and there is no spring for avoiding the spring fatigue problem. In figure 5 and figure 6, the CFRP elastic material is also used for improvement the dynamic characteristics. Figure 7 is the experimental setup for the performance measurement of the fabricated piezoelectric actuator and general solenoid actuator. The experimental setup consists of a fixed jig, a laser sensor, a force sensor and a frequency analysis equipment. Figure 8 shows the experimental results of the actuator displacement and blocking force. In the experimental results, x-axis is the voltage inputted to the actuator, and left-y-axis and right-y-axis are the displacement and the blocking force of the manufactured actuator. The minimum and the maximum value of the actuator displacement are 150 μm at 50 V input and 350 μm at 120 V input, respectably. We can know that the output displacement of the manufactured actuator is proportional to the input voltage and displacement results are very linear. The blocking forces of the actuator are from 300gf to 470 gf and over when input voltages are 80 V and 120V, respectably. Figure 5 Photo view of the manufactured actuator a) Experimental setup for the piezoelectric actuator a) Off state b) On state Figure 6 Operating principal of the manufactured piezoelectric actuator b) Experimental setup for the frequency response characteristics measurement for solenoid actuator Figure 7 Experimental setup for the fabricated piezoelectric actuator test

4 controller Figure 8 Experimental results of displacement and blocking force Figure 10 shows the two kinds of control method for solenoid and piezoelectric valve. In case of solenoid valve of a) of figure 10, the attraction force is greater when the length between core and plunger is short. So, low input voltage makes operate the solenoid valve in case of reasonable range between core and plunger. This means that the maximum input voltage doesn t need for low energy consumption. The other method is to control the piezoelectric valve using PFM method. The PFM method is very important control strategy because the grain arrangement is unity and the drop down speed of the grain is only changed by the feeder and the chute. PIEZOELECTRIC VALVE FOR THE GRAIN SORTING SYSTEM Figure 9 shows the assembled piezoelectric valve and its controller. The prototype piezoelectric valve of figure 9 is for controlling the air ejector and tube plumbing having a small volume doesn t need for high-speed response characteristics. a) Control strategy using solenoid controller a) Assembled piezoelectric valve b) PFM control strategy for piezoelectric valve Figure 10 Control strategies for solenoid valve and piezoelectric valve using controller b) Controller for piezoelectric valve Figure 9 Assembled piezoelectric valve and its Figure 11 is the experimental circuit and the experimental setup for performance evaluation of the manufactured piezoelectric valve, and the test circuit of the figure 11 was built according to the ISO In this study, a matter of concern is to check of pressure variation at the outlet port because the manufactured valve is better or not than the conventional type solenoid valve. So, pressure sensors were equipped to the air tank and outlet port of the tested valve. The b) of figure 11 presents the experimental setup for performance and endurance test for the fabricated valve.

5 The PC with AD converters and some amplifiers for data measurement were installed and the function generator for PFM control is also equipped to experimental setup. The endurance test was conducted under the condition of no-load and 0.4 MPa-load. type solenoid valve. It was confirmed from figure 12, b) that the flow performance of the 3 rd prototype valve is superior to the conventional type solenoid valve. This means that the 3 rd prototype valve can remove the more heavy foreign body in the grain sorting system. Finally, we had operated the endurance test using the 3 rd prototype valve, and we confirmed that the endurance number is 10 billion and over. a) Pneumatic circuit for experiment a) 2 nd prototype piezoelectric valve vs. conventional type solenoid valve b) Experimental setup for performance & endurance test for the fabricated valve Figure 11 Experimental circuit and setup for performance test of the manufactured piezoelectric valve. Figure 12 shows the experimental results of the pressure characteristics of the valve outlet port. The x-axis is the time and y-axis is the output voltage which means the pressure variation. And the symbol, DW224, means the solenoid valve, and KW 2 nd and KW 3 rd mean the 2 nd and 3 rd prototype piezoelectric valve, respectably. The meaning of the same pressure peak result is that the flow rate at outlet port is also the same because of the same orifice and the same volume. In case of 2 nd prototype of figure 12, a), the on-process, such as the delay time and peak time, is equivalent to the conventional type solenoid actuator but the off-process is a few late about 150 μs. We can know from the figure 12, a) that the on-off characteristics of the manufactured piezoelectric valve are equivalent to the conventional type solenoid valve one and that the manufactured valve has a possibility to use for the grain sorting valve. Figure 12, b) shows the results comparison between the 3 rd prototype piezoelectric valve versus conventional b) 3 rd prototype piezoelectric valve vs. conventional type solenoid valve Figure 12 Experimental results of the outlet pressure (DW224 means the solenoid valve and KW 2 nd KW 3 rd mean the prototype piezoelectric valve)

6 CONCLUSIONS /SAE OH , 2002, pp In this study, the 2 nd and the 3 rd prototype piezoelectric valve for an ejector of the grain sorting system were designed and fabricated, and the experimental setup for the performance evaluation was manufactured. The results of this study are as follows; 1. The maximum displacement and the maximum blocking of the fabricated actuator of which ceramic sheet thickness of 40 μm and layers of 9 for overcoming the input pressure of 0.4MPa are 350 μm and 470gf, respectably. 2. The piezo valve and the controller were suggested and PFM control method was conducted. 3. We had operated the endurance test using the 3 rd prototype valve, and we confirmed that the endurance number is 10 billion and over. 4. It was confirmed that the new type piezo pneumatic valve is possible to use to the ejector for grain sorting system. REFERENCES 1. Zhong Xiang, Hao Liu and Guoliang Tao, Development and investigation of high-speed pneumatic jet valves by lumped parameter modeling, 7 th International Fluid Power Conference, 2010, pp Tomohiko Katagiri, High-speed strategy of solenoid valve, Fluid power system, Vol.41, No.5, 2010, pp M. Weinmann, A. J. Schmid, M. Fuss, Piezoelectric pneumatic valves, Actuator 2006-A5.2, 2006, pp So-Nam Yun, Kyung-Woo Lee, Hong-Hee Kim and Hyung-Jong So, Development of the pneumatic valve with bimorph type piezoelectric actuator, Materials chemistry and physics, 2006, pp So-Nam Yun, Young-Bog Ham, Jung-Ho Park, Woo-Seok Seo and Kyung-Woo Lee, Electro-pneumatic regulator strategy using two PZT actuator, ATEM 07, 2007, p M. Weinmann, M. Muth, M. Giousouf, C. Hanisch and P. Post, State of the art in pneumatic microvalves, Actuator 2002-B 1.0, 2002, pp P. Mandurino and P.M. Weaver, Electronic domestic gas valve proportionally controlled using piezo actuators, Actuator 2004-A4.7, 2004, pp Hubertus Murrenhoff, Innovative designs and control circuits for proportional valves, NCFP

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