Direct-drive electro-hydraulic servo valves are widely used in the aerospace industry, in the military, and in remote sensing control, but there is little research and discussion on their performance degradation and service life prediction. Based on previous research, erosion wear is the primary physical failure form of direct-drive electro-hydraulic servo valves, and parameters such as opening, oil contamination, and pressure difference are used as influencing factors of direct-drive electro-hydraulic servo valves. Pressure gain and leakage are used as performance degradation indicators of servo valves, and multiple types of sensors are used for data monitoring. Experimental benches are arranged and verified through experiments. Based on the data and laws obtained from the experiments, the exponential smoothing algorithm and the ARIMA model algorithm were used to establish a prediction model for the servo valve, and the dynamic prediction of the performance indexes was carried out. The error calculation and analysis of the prediction results and the experimental results were then carried out using the Copula function and other mathematical knowledge to verify the accuracy and applicability of this prediction model. This study provides theoretical support and practical guidance for applying and designing direct-drive electro-hydraulic servo valves in industrial applications such as aerospace, sensor experiments, and remote sensing control.

Direct-drive electro-hydraulic servo valves are used extensively in aerospace, military and control applications, but little research has been conducted on their service life and physical failure wear. Based on computational fluid dynamics, the main failure forms of direct-drive electro-hydraulic servo valves are explored using their continuous phase flow and discrete phase motion characteristics, and then combined with the theory of erosion for calculation. A mathematical model of the direct-drive electro-hydraulic servo valve is established by using Solidworks software, and then imported into Fluent simulation software to establish its physical failure model and carry out simulation. Finally, the physical failure form of the direct drive electro-hydraulic servo valve is verified by the simulation results, and the performance degradation law is summarized. The results show that temperature, differential pressure, solid particle diameter and concentration, and opening degree all have an impact on the erosion and wear of direct-drive electro-hydraulic servo valves, in which differential pressure and solid particle diameter have a relatively large impact, and the servo valve must avoid working in the range of high differential pressure and solid particle diameter of 20–40 um as far as possible. This also provides further theoretical support and experimental guidance for the industrial application and life prediction of electro-hydraulic servo valves.

Physical dynamic characteristics and control studies were conducted for pneumatic artificial muscle (PAM), the core component of the drive of lower limb rehabilitation robots. Firstly, a static model and a dynamic model of the pneumatic artificial muscle were established. Then a test bench was designed to perform dynamic characteristic test simulations and experiments. After that, the pneumatic artificial muscle test bench was designed to simulate and test its dynamic characteristics. Finally, a typical PID (Proportional Integral Derivative) controller was built to perform control simulations and step control experiments for the pneumatic artificial muscle. Experiments show that the PID can achieve stable and accurate tracking of the signal and meet the application requirements of PAM.

Direct-drive electro-hydraulic servo valves play a key role in aerospace control systems, and their operational stability and safety reliability are crucial to the safety, stability, and efficiency of the entire control system. Based on the prediction of the performance change of the servo valve and the resulting judgement and prediction of its life, this can effectively avoid serious accidents and economic losses caused by failure due to performance degradation in the work. On the basis of existing research, factors such as opening, oil contamination, and pressure difference are used as prerequisites for the operation of direct-drive electro-hydraulic servo valves. In addition to the current research on pressure gain and leakage, the performance parameters of servo valves, such as overlap, threshold, and symmetry, are also expanded and selected as research objects, combined with pressure design servo valve performance degradation experiments for testing instruments such as flow and position sensors, and data are obtained on changes in various performance parameters. The experimental data are analyzed and a prediction model is built to predict the performance parameters of the servo valve by combining the existing popular neural networks, and the prediction error is calculated to verify the accuracy and validity of the model. The experimental results indicate that as the working time progresses, the degree of erosion and wear on the valve core and valve sleeve of the servo valve increases. Overall, it has been observed that the performance parameters of the servo valve show a slow trend of change under different working conditions, and the rate of change is generally higher under high pollution (level 9) conditions than under other conditions. The prediction results indicate that the predicted values of various performance parameters of the servo valve by the prediction model are lower than 0.2% compared to the experimental test set data. By comparing the two dimensions of the accuracy and prediction trend, this model meets industrial needs and outperforms deep learning algorithm models such as the exponential smoothing algorithm and ARIMA model. The experiments and results of this study provide theoretical support for the life prediction model of servo valves based on neural networks and machine learning in artificial intelligence, and provide a reference for the development of direct-drive electro-hydraulic servo valves in aerospace and other industrial fields for use and failure standards.