Development of a Novel Digital Pressure Control Valve Applied to Emulsion Pump Station Control and Research on the Performance of Its Dynamic Characteristics

To advance the construction of intelligent mining, electro-hydraulic digital control technology has emerged as a critical direction for the digital transformation of mining machinery. This study proposes a digital control scheme based on the pressure state of the system and the operating state of the actuator. The scheme utilises a novel convergence rate sliding film position control method to regulate the system pressure in real time by controlling the pilot valve, which is driven by a permanent magnet synchronous motor (PMSM). Moreover, a prototype of an incremental digital pressure control valve was developed for high-pressure, high water-based working conditions. A simulation model of the valve was established using AMESim/Simulink, and dynamic characteristics under various operating conditions were analyzed. The relative error between simulated and experimental pressure results remained within ±4.7%. Finally, a multi-parameter optimization was conducted using a genetic algorithm. The results demonstrate that the optimized digital pressure control valve achieved a stabilized inlet pressure within 44.8 ms, with a pressure overshoot of 4.1% and a response time of 20.1 ms, exhibiting excellent real-time dynamic pressure regulation capabilities. This study provides a theoretical foundation and practical reference for comprehensive research on pressure control in underground emulsion pump stations.