In modern industrial hydraulic systems, the ability to precisely control pressure, force and axis motion represents a decisive competitive factor. The most demanding applications require systems capable of simultaneously managing different physical quantities, smoothly transitioning from speed control to force control, without compromising dynamics and repeatability.
ATOS addresses this need with a complete digital electrohydraulic ecosystem, where high-performance servo valves, TEZ axis controllers with autotuning and integrated p/Q functions work in synergy to offer ready-to-use solutions. This article analyzes in detail how these components interact to ensure superior performance in the most critical industrial applications.
The ATOS digital proportional servo valves form the central core of every high-performance electrohydraulic system. The range includes direct and pilot-operated directional valves, available both in servo-proportional version with zero-lapped spools and in high-performance proportional version with positive overlap.
The DLHZO-TEZ and DHZO-TEZ series servo valves represent the direct solution with zero-lapped spools, ideal for high-precision closed-loop position controls. The pilot-operated DPZO-LEZ versions extend these capabilities to larger sizes while maintaining the same performance characteristics.
Each valve integrates an LVDT transducer for spool position feedback, ensuring extremely accurate closed-loop control. Digital spool regulation through the integrated LVDT transducer provides fast and repeatable response, essential in applications where precision is a mandatory requirement.
ATOS digital valves are CE marked according to applicable Directives, including the EMC Directive for immunity and emission, and offer extremely robust construction features: shock resistance up to 100g with optional damping plate, operating temperature range from -40°C to +60°C and IP66/67 protection rating.
TEZ represents the ATOS solution for complete electrohydraulic axis control. It is a system that integrates digital driver and axis board directly on the servo-proportional valve, creating a compact unit capable of performing position, speed and force controls on any electrohydraulic axis.
The TEZ system is available both in on-board version, integrated directly on the valve, and in off-board version (Z-BM-TEZ) for electrical cabinet installations. This flexibility allows adapting the solution to specific system requirements while maintaining unchanged control functionality.
Servo-proportional valves with integrated TEZ controller interface with external position transducers, electrical power supply, electronic signals and field buses, constituting a complete system for axis management. Real-time trajectory generation, performance monitoring and accurate positioning are native system functions.
One of the distinctive features of the TEZ system is the autotuning function, which significantly simplifies axis commissioning. This function allows automatic optimization of control parameters based on the actual characteristics of the hydraulic system, reducing commissioning time and ensuring optimal performance from the first start-up.
The operational advantages of the TEZ system include reduced commissioning time thanks to automatic parameter optimization, greater system stability through adaptive adjustments to actual operating conditions, and the ability to monitor axis performance in real time through dedicated software.
The ATOS PC software, freely downloadable from the MyAtos area of the official website, allows setting all functional parameters and accessing complete diagnostic information through the Bluetooth or USB service port. The integrated oscilloscope enables analyzing the dynamic behavior of the system and optimizing adjustments.
p/Q control represents one of the most advanced functionalities of ATOS digital proportional valves. This function adds closed-loop pressure or force control to standard direction and flow regulation, allowing management of actuator speed, position and force with a single valve.
Three options are available:
Switching between flow control and force control occurs automatically thanks to a dedicated algorithm. Flow regulation remains active when the measured actual force is lower than the corresponding reference signal. When force reaches the defined setpoint, control automatically switches to force regulation, reducing flow to maintain the set value constant.
The switching dynamics between the two controls can be adjusted through specific software settings to avoid instability or vibrations. Up to four different PID parameter sets can be selected to optimize dynamic response based on different hydraulic working conditions.
Valves with p/Q control find application in numerous industrial settings. High-dynamics pressure reduction control uses valves with zero-lapped spools in three-way configuration to precisely regulate pressure at the work port.
Single-acting actuators benefit from speed/pressure or speed/force control, where the flow reference regulates speed while the pressure or force reference limits maximum effort, or vice versa. For double-acting actuators, SF and SL options allow controlling force in both push and pull directions.
Two main operating modes characterize operation: flow priority, where the flow reference signal controls movement while force is limited, and force priority, where the force reference manages push and pull forces while flow is limited.
ATOS servo cylinders are designed to integrate perfectly with TEZ control systems. Equipped with integrated position transducer, these actuators provide the feedback necessary for closed-loop position control.
Robust construction and machining tolerances ensure high performance in terms of precision and repeatability. Servo cylinders are available in different configurations to adapt to specific application requirements in terms of stroke, diameters and operating pressures.
Integration between servo cylinder and TEZ system occurs through connection of the position transducer to the axis board. The servo cylinder with position transducer, servo-proportional valve and integrated TEZ controller form a complete system for axis control.
For applications that also require force control, adding pressure transducers on the actuator ports or a load cell enables p/Q functions. The SF option with two pressure transducers allows adding force control even to existing systems with a relatively simple installation intervention.
ATOS digital electronic drivers represent the system's intelligence, managing all control and interface functions. Available in on-board version integrated on the valve or off-board for DIN rail mounting, the drivers offer complete connectivity with the main industrial field buses.
Supported fieldbus interfaces include CANopen, PROFIBUS DP, EtherCAT, POWERLINK, EtherNet/IP and PROFINET, ensuring integration with any automation architecture. Real-time access to parameters, transducers and diagnostics enables complete system management.
The USB port with optional Bluetooth adapter allows configuration and diagnostics through the ATOS CONNECT mobile app or Windows PC software. Alarm history and integrated oscilloscope are valuable tools for predictive maintenance and troubleshooting.
TÜV-certified safety functions complete the offering for applications where functional safety is a regulatory requirement.
The real strength of the ATOS offering lies in the integration of all components into a coherent ecosystem. Servo valve, TEZ controller, p/Q functions, servo cylinder and digital driver communicate through standardized protocols, offering a plug-and-play solution for electrohydraulic axis control.
This integration translates into concrete advantages: reduced design time thanks to components pre-engineered to work together, simplified commissioning through autotuning functions, complete diagnostics for efficient maintenance and guaranteed performance from perfect compatibility between components.
The ATOS integrated system therefore represents a reliable and high-performance solution for electrohydraulic axis control, particularly suitable for those operating in sectors such as injection molding, die casting and metal forming, where precision, repeatability and reliability are essential requirements.