Energy efficiency mapping-based dual-loop anti-disturbance control for active load-sensitive drive system

With the continuous development of science and technology and the growing severity of energy issues, load-sensitive drive systems have attracted significant attention in the electro–hydraulic servo field due to their high energy efficiency. Currently, most research primarily focuses on introducing load-sensitive valves to achieve load-following through hydraulic-mechanical feedback. This approach has partially achieved the energy-saving goal, but issues such as reduced dynamic response speed and limited load-sensitive range due to mechanical structures remain. This paper proposes an active load-sensitive variable displacement drive system that no longer relies on mechanical structures for load-sensitive adjustment. And multiple energy efficiency mapping relationships are designed to complete the system’s load-sensitive adjustment, thereby reducing throttling losses. Additionally, a dual-loop anti-disturbance control method based on energy efficiency mapping is proposed. An appropriate Lyapunov function is selected to prove that the control system ultimately tends to be bounded and stable, successfully solving the multiplicative nonlinear coupling control problem caused by the variable mechanism, and improving the system’s position control accuracy. Experimental results show that under this control method, the active load-sensitive drive system can reduce flow by up to 60 % compared to the traditional fixed displacement hydraulic motor drive system. Compared to conventional PID control, the proposed method can improve control accuracy by up to 50 %, effectively reducing energy consumption while improving the position control accuracy of the active load-sensitive variable motor drive system.