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Proportional vs. Servo Valves: When You Need Closed-Loop Hydraulic Control

A proportional valve and a servo valve both meter hydraulic flow in proportion to an electrical command, but they differ in precision, speed, and repeatability, which bears on whether a heavy hydraulic axis can hold a position, follow a profile, or regulate a force under load. UTEC Industrial designs, engineers, machines, fabricates, and installs custom material handling systems for aerospace and heavy industry from its Spokane Valley, WA facility, integrating Allen-Bradley PLC and motion control with in-house CNC machining, heat treating, and stress relief. This article compares the two valve classes on data-sheet figures (hysteresis, response sensitivity, bandwidth, deadband, and cleanliness class) and shows how to judge when an axis needs closed-loop control. Valve choice sits late in the build chain, design → engineering → parts machining → fabrication → assembly → weld fatigue → stress relief → drives → controls → tuning → monitoring, but it depends on decisions made at the first links: the moving mass, the cylinder geometry, and the stiffness of the frame the cylinder pushes against.

What is the difference between a proportional valve and a servo valve?​

Both are continuously variable directional valves: unlike an on/off solenoid valve, they open an orifice by an amount that follows the electrical command, so the flow to the actuator, and its speed, follow the command too; where they differ is in precision, speed, and repeatability.

A proportional directional valve of the Bosch Rexroth 4WRE/4WREE type (figures here are from data sheet RE 29061, edition 10.05) is a direct-operated, spring-centred spool valve driven by proportional solenoids. It carries a position transducer on the spool, and its data sheet describes it as providing closed-loop control of both the direction and the size of a flow. The integrated-electronics version accepts a ±10 V or 4 to 20 mA command and returns a spool actual-value signal. It is rated to 315 bar (about 4,570 psi) on ports A, B, and P, with nominal flows of 8, 16, or 32 l/min in nominal size 6 and 25, 50, or 75 l/min in nominal size 10, each measured at a 10 bar valve pressure differential.

In NASA's analysis of a servovalve-controlled actuator, the servovalve spool is modeled as a first-order system whose time constant is set by the servovalve bandwidth, which is typically specified by the manufacturer; the example valve in that report is rated at 25 Hz bandwidth and 40 gpm at 1,000 psi pressure loss, working from a 3,000 psig supply.

As engineering reasoning, then, a proportional valve is chosen on flow, pressure rating, and spool-position accuracy, and a servo-grade valve on bandwidth and low deadband, because its axis loop has to correct errors faster than the load drifts. The response and accuracy figures on the data sheet matter more than the valve's name (Bosch Rexroth RE 29061/10.05, Features and Technical data; NASA-TM-101644 1990, §2.2 and Table I).

What does "closed-loop" actually close in a hydraulic motion system?​

Two different loops are involved, and a specification can confuse them.

The first is the valve's own spool loop. On a proportional valve with electrical position feedback, the onboard or external amplifier compares the command with the spool position transducer and drives the solenoids until the spool reaches the commanded position. The Rexroth data sheet notes that, when de-energised, the spool is held in a mechanical centre position by its return springs, and for the "V" spool that mechanical centre is not the hydraulic centre. Only when the electrical valve control loop is closed is the spool positioned at the hydraulic centre.

The second is the axis loop, which closes around the actuator itself. A cylinder position transducer, chamber pressure transducers, or a load cell feeds a controller that adjusts the valve command until position, pressure, or force matches the setpoint. Without this outer loop, a perfectly controlled spool still delivers only a controlled flow; actuator position is the time integral of that flow, and it drifts with load, leakage, temperature, and supply pressure.

An experimental comparison of hydraulic, pneumatic, and electric linear actuators at the University of Ljubljana ran the hydraulic axis on a 4/3 proportional directional valve with a step command and no feedback loop. The authors concluded that smooth, constant motion from a hydraulic or pneumatic system requires a feedback loop controller that sets the valve opening as needed. "Closed-loop hydraulics" in a specification should therefore name which variable the axis loop regulates and which sensor measures it (Bosch Rexroth RE 29061/10.05, Function section; Pustavrh et al. 2023, Experimental setup and Conclusion).

Which datasheet numbers separate a proportional valve from a servo-grade valve?​

Four groups of figures map to what the axis loop can achieve. The Rexroth values are measured with HLP46 oil at 40 °C ± 5 °C and 100 bar.

FigureWhat it tells the specifierExample value from the register sources
HysteresisDifference in spool position for the same command approached from opposite directions≤ 0.1 % on the Rexroth 4WRE/4WREE
Reversal span and response sensitivityCommand change needed to reverse the spool, and the smallest command change that produces spool movement≤ 0.05 % each on the 4WRE/4WREE
Zero-point displacementDrift of the hydraulic zero with oil temperature and pressure0.15 % per 10 K and 0.1 % per 100 bar on the 4WRE/4WREE
Bandwidth and deadbandHow fast the spool follows a changing command, and how much command produces no flow25 Hz bandwidth and ±2 % deadband on the NASA example servovalve

The Rexroth data sheet also publishes step-response (transient-function) curves, plotted on a 0 to 40 ms time axis for nominal size 6 and 0 to 60 ms for nominal size 10, and frequency-response curves from 1 to 200 Hz, both measured at ps = 10 bar. The frequency-response chart plots a separate curve for each of three signal amplitudes, ±10 %, ±25 %, and ±100 %, so a specifier should read the curve at the amplitude the application uses rather than quote a single bandwidth figure.

A specification that asks only for "a proportional valve" or "a servo valve" leaves these figures open; one that states the positioning resolution, move profile, and tolerable deadband lets a supplier select the valve grade and show the data sheet that proves it (Bosch Rexroth RE 29061/10.05, Technical data and characteristic curves; NASA-TM-101644 1990, Table I).

How do spool overlap and deadband affect positioning accuracy?​

A spool can be made with overlap, meaning the lands cover the ports by a small distance at the neutral position. NASA's report states that a servovalve spool may be manufactured with overlap to ensure positive shutoff, and that an overlapped spool results in a deadband about the neutral position and acts to increase system damping. The example valve in the report has a deadband of ±2 %.

As engineering reasoning, deadband is a band of command in which nothing happens. Near the target the controller's correction is small; if it falls inside the deadband, the actuator stops short, the controller output integrates upward until it breaks through, and the axis jumps past the target. The result is a limit cycle: a small sustained hunt, seen as chatter on a positioner or a lift holding position.

NASA also lists the assumptions used to linearize the system equations, and zero servovalve overlap is one of them. In engineering terms, a zero-lap spool behaves like the linear model; an overlapped spool gives positive shutoff but is harder to control near zero. The Rexroth data sheet's note that, on its "V" spool, the mechanical spring centre differs from the hydraulic centre is a related point on the proportional-valve side. For a holding axis, the specifier decides whether positive shutoff (overlap plus a load-holding valve) or fine control through zero (a low-deadband valve) governs (NASA-TM-101644 1990, §2.2 and §2.5; Bosch Rexroth RE 29061/10.05, Function section).

When does an open-loop proportional valve stop being good enough?​

Open-loop proportional control, a speed command to the valve with limit switches or proximity sensors to stop the move, can be adequate for heavy axes such as a log turner that rotates until a sensor trips, a gate that opens to a hard stop, or a clamp that closes until pressure builds. It stops being adequate when the axis has to arrive somewhere precise, follow a speed profile under a changing load, or hold a force.

The Ljubljana experiment shows why. Under a step command with no feedback loop, the hydraulic actuator reached its highest velocity, 0.76 m/s, at the start of the stroke and then settled to 0.18 m/s. At a 200 bar system pressure with the added load on the carriage, three periods of oscillation followed the valve switching, the first lasting 0.51 s and the next two about 0.17 s and 0.16 s. The authors attributed the initial surge to potential energy stored in the pressurised lines being released when the valve opened, and noted that hydraulic accumulators help prevent sudden releases of high energy or pressure shocks.

NASA's simulations point the same way: the acceleration of the piston and load is determined by the rate of change of the servovalve command, while the magnitude of the command sets the slew rate. A 30 % step command produced large accelerations and visible oscillation; ramped commands of 150 %/s and 60 %/s to the same 30 % opening reduced peak acceleration, and in the gentler case oscillation was almost non-existent.

Command ramping, which the Rexroth integrated electronics provide with an externally adjustable ramp of 0 to 2.5 s, addresses the acceleration problem. As engineering reasoning, it does not fix drift, load-dependent speed, or position error at the end of the move; that takes an axis loop. UTEC Industrial proves those ramps and loops out on the assembled machine during factory acceptance testing and again at on-site commissioning (Pustavrh et al. 2023, Results and Conclusion; NASA-TM-101644 1990, §4.1 to §4.3; Bosch Rexroth RE 29061/10.05, Integrated electronics).

How fast does the valve need to be compared with the load?​

The answer comes from comparing the valve's bandwidth with the hydraulic natural frequency of the actuator and its load. NASA derives the transfer function of a servovalve-controlled actuator. For a double-acting actuator with equal areas operating about midstroke, the hydraulic natural frequency is:

ω_N² = 2 B A² / (V M)

where B is the fluid bulk modulus, A the piston area, V the oil volume on each side of the piston, and M the moving mass. The oil column acts as a spring, and the moving mass resonates on it.

A worked check using the parameters in NASA's own example:

  • Bulk modulus, B = 100,000 psi (the constant in the report's simulation code)
  • Cylinder bore 2.0 in, so A = π × 2.0² ÷ 4 = 3.14 in²
  • Stroke 15 in (Table I); at midstroke, V = 3.14 in² × 7.5 in = 23.6 in³ per side
  • Mass of piston and load 2,050 lbm, so M = 2,050 ÷ 386.4 = 5.31 lbf·s²/in

ω_N² = 2 × 100,000 psi × (3.14 in²)² ÷ (23.6 in³ × 5.31 lbf·s²/in) ≈ 15,800 s⁻², so ω_N ≈ 126 rad/s and f_N ≈ 20 Hz.

Assumptions: the actuator is treated as equal-area using the 2.0 in bore, although NASA's actual cylinder has a 1.375 in rod and unequal areas; line and valve-port volume is ignored; and the cylinder mount is taken as rigid.

The example valve's 25 Hz bandwidth sits close to the 20 Hz load resonance; modelled as a first-order lag, that bandwidth gives a spool time constant of τ = 1 ÷ (2π × 25) ≈ 6.4 ms. The valve's first-order lag and the second-order load term then both appear in the transfer function. Because f_N varies with 1 ÷ √M, a load ten times heavier on the same cylinder drops the natural frequency to about 6.3 Hz, and doubling the trapped oil volume with long hoses to a remote valve drops it to about 14 Hz. As engineering reasoning, a heavy, slow axis may not need a high-bandwidth valve; it needs a valve mounted close to the cylinder, short stiff lines, and a frame that does not add its own compliance (NASA-TM-101644 1990, §2.5 Eq. 27 to 29, Table I and Appendix 7.0).

How is valve flow sized against pressure drop and load?​

Flow through a metering spool is not linear in pressure. NASA models servovalve flow as a function of the square root of the differential pressure across the valve, Q = K_v √ΔP, and computes the coefficient from the manufacturer's rating. For the example valve rated at 40 gpm at 1,000 psi loss, K_v = 3.851 × 40 ÷ √1,000 ≈ 4.87 in⁴/(s·lbf^0.5). The same relationship means that if only 250 psi is left across the valve after the load takes its share of supply pressure, the fully open valve passes about 40 × √(250 ÷ 1,000) = 20 gpm, half its rating.

The Rexroth proportional valve is rated the same way at a lower reference pressure: its 4WRE/4WREE nominal flows are stated at a 10 bar (145 psi) valve pressure differential, defined as inlet pressure minus load pressure minus return pressure, with a maximum permissible flow of 80 l/min (about 21 gpm) for nominal size 6 and 180 l/min (about 48 gpm) for nominal size 10. A 32 l/min valve run at 40 bar across the spool would pass about 64 l/min by the square-root relation, still inside the 80 l/min limit; the data sheet instructs the user to take that maximum into account.

The hydraulic power the valve controls follows directly as P = pQ. NASA's step case drew a peak of about 15 gpm into the cap end from a 3,000 psig supply; at full supply pressure that is 3,000 × 15 ÷ 1,714 ≈ 26 hp (about 19.6 kW), an upper bound on the hydraulic power one valve spool meters in that case. Sizing therefore starts from the load force and speed, sets the pressure left across the valve at full speed, and only then picks the valve's rated flow (NASA-TM-101644 1990, §2.2 Eq. 11 to 13; Bosch Rexroth RE 29061/10.05, Technical data and flow curves; Kazama 2019, Eq. 1).

Why do high-flow servo valves use multiple stages and feedforward control?​

The Rexroth 4WRE is a direct-operated valve: energising one of its proportional solenoids moves the control spool directly. Very high-flow servo valves are built in stages, a smaller stage driving a larger one. Lee and co-authors note that three-stage servo-valves are popularly used in hydraulic systems that require large flow rate and high pressure, and that securing a proper position-control bandwidth is a critical task for the servo-valve.

The authors systematically studied a set of popular control methods for the three-stage valve's position control and report feedforward model-inverse control as the most effective in terms of control bandwidth. On recognizing a nonminimum-phase zero problem in the estimated closed-loop model, they applied zero magnitude error tracking control, an approximate model-inverse technique, to overcome it.

As engineering reasoning, the valve's internal control strategy is part of its performance: a high-flow axis on a large press or gate hoist may need a multi-stage valve with its own tuned spool loop inside the PLC axis loop, and two loops tuned by two parties need a stated bandwidth boundary (Lee et al. 2019, Abstract).

Why does fluid cleanliness decide whether a proportional or servo valve survives?​

Metering spools run with small clearances, and, as engineering reasoning, the performance figures above depend on oil clean enough not to wear or jam them. The Rexroth data sheet sets a maximum permissible contamination of cleanliness class 20/18/15 to ISO 4406 for the 4WRE/4WREE, states that the cleanliness class stated for the components must be adhered to in hydraulic systems, and notes that effective filtration prevents faults and increases component service life. ISO 4406:2021 specifies the code used to define the quantity of solid particles in the fluid of a hydraulic fluid power system.

The same valve is specified for a viscosity range of 20 to 380 mm²/s, with 30 to 46 mm²/s preferred, and a fluid temperature range of −20 to +80 °C, with +40 to +50 °C preferred. Its zero point shifts by 0.15 % per 10 K with changes to the fluid and operating temperature, so, as engineering reasoning, a machine that starts cold and warms up over a shift will see its valve null move unless the axis loop corrects it.

As engineering reasoning, failure modes follow from those clearances: silt wearing the metering edges raises leakage and deadband, a lodged particle sticks the spool, and varnish increases hysteresis. These tend to appear first as slower settling, a growing position error, or a limit cycle at standstill rather than a hard fault. A specification should make the target cleanliness code, filter locations, and oil-temperature conditioning acceptance items (Bosch Rexroth RE 29061/10.05, Technical data note 1; ISO 4406:2021).

How do controls and sensing close the loop in an Allen-Bradley PLC system?​

The intelligence layer around a closed-loop hydraulic axis comprises sensors, the controller task that runs the loop, the valve interface, and monitoring.

  • Sensors. A linear position transducer on the cylinder for position control, pressure transducers on both chambers for force or pressure control, and a load cell where force must be measured directly in the load path. The Ljubljana hydraulic test rig carried this kind of instrumentation: a linear position sensor, four pressure sensors, a load cell, a flow sensor, and a temperature sensor.
  • Loop execution. In a Logix 5000 controller, a periodic task executes automatically based on a preconfigured interval, and it does not execute again until the configured interval has elapsed. As engineering reasoning, that fixed interval is what a sampled control loop needs. An event task can respond to a trigger, and Rockwell notes that the motion planner takes precedence over event and periodic tasks.
  • Valve interface. The integrated electronics on the Rexroth 4WREE take a ±10 V or 4 to 20 mA command and return a matching actual-value signal of the spool position, which the PLC can compare with the command to detect a stuck or drifting spool.
  • Electrical design basis. IEC 60204-1:2016+AMD1:2021 applies to the application of electrical, electronic, and programmable electronic equipment and systems to machines not portable by hand while working, which takes in the panel, wiring, and drive circuits.

UTEC Industrial programs Allen-Bradley ControlLogix and CompactLogix controllers with PanelView and FactoryTalk operator interfaces over EtherNet/IP, and builds the control panels to UL 508A. Monitoring completes the chain: logging following error, standstill valve command, and oil temperature against the 0.15 % per 10 K null shift can give early warning of contamination and wear (Rockwell Automation 1756-RM094N-EN-P-2025, Configure a Periodic Task p. 43; Bosch Rexroth RE 29061/10.05, Integrated electronics; Pustavrh et al. 2023, Hydraulic system; IEC 60204-1:2016+AMD1:2021).

Can the valve's feedback signal be used for a safety function?​

No, and the valve manufacturer says so explicitly. The Rexroth 4WRE/4WREE data sheet states that electrical signals processed by the control electronics, such as the spool actual value, must not be used for switching off safety-relevant machine functions. The spool feedback exists to make the valve meter accurately; it is not a safety-rated signal.

Safety functions on a hydraulic axis, such as safe stop, load holding, and guarding or zone interlocks, belong in a safety-rated control system.

The standards that frame the risk assessment and design of that system are ISO 12100:2010, which specifies principles of risk assessment and risk reduction, and ISO 13849-1:2023, which specifies a methodology and provides related requirements, recommendations and guidance for the design and integration of safety-related parts of control systems that perform safety functions, for high demand and continuous modes of operation, regardless of the type of technology and energy, hydraulic included. As engineering reasoning, where the de-energised state is the safe state, the spool position on dropout and the circuit's holding elements must leave the load stationary rather than free to fall or drift, a circuit-design decision made before the safety PLC is programmed (Bosch Rexroth RE 29061/10.05, Integrated electronics note; ISO 12100:2010; ISO 13849-1:2023).

What stored-energy hazards does a closed-loop hydraulic axis add at lockout?​

A closed-loop hydraulic axis can carry an accumulator, either to supply the peak flows that fast valves demand or to absorb pressure shocks. NASA's example system includes a 5 gallon accumulator with an 1,800 psia initial gas charge and a 3,000 psig supply, and the Ljubljana authors note that installing hydraulic accumulators helps prevent sudden releases of high energy potential or pressure shocks. An accumulator charged like that holds energy in the circuit after the pump motor is locked out.

OSHA's lockout/tagout standard defines an energy source to include hydraulic and pneumatic energy, and paragraph 1910.147(d)(5)(i) requires that, after lockout or tagout devices are applied, all potentially hazardous stored or residual energy be relieved, disconnected, restrained, and otherwise rendered safe. Paragraph 1910.147(d)(5)(ii) requires verification of isolation to continue until the servicing or maintenance is completed, or until the possibility of such accumulation no longer exists, if stored energy could reaccumulate to a hazardous level. In engineering terms, on a hydraulic axis that means accumulator dump valves, gauge points to verify zero pressure, and mechanical blocking for any load held up by a cylinder, because trapped oil behind a closed valve can still support, or suddenly release, a raised load.

ISO 4413:2010 specifies general rules and safety requirements for hydraulic fluid power systems and components used on machinery; this library identifies it at scope level only. The practical specification items are an accumulator isolation and discharge arrangement, a pressure gauge visible from the isolation point, and a written energy-control procedure for each axis (OSHA 29 CFR 1910.147-1989, paragraph d.5; NASA-TM-101644 1990, Table I; ISO 4413:2010).

When is an electric servo axis the better choice than closed-loop hydraulics?​

Not every precise axis should be hydraulic. The Ljubljana comparison limited the input power of its hydraulic, pneumatic, and electric linear actuators to 1.1 kW (the hydraulic unit's electric motor and the compressor are each rated 1.1 kW) and found that the electric system gave the most consistent response and the lowest power consumption. The hydraulic system drew 740.5 W before activation at a 50 bar system pressure and 1,529.9 W at 200 bar, because its power unit runs whether or not the valve is commanded; the paper reports that measured draw without reconciling it with the 1.1 kW limit. The complete hydraulic system also weighed 52.0 kg against 11.6 kg for the electric system and 7.9 kg for the pneumatic one.

In the same study the hydraulic actuator produced the highest measured compressive and tensile forces during the test moves, and Kazama's survey of transmission elements found that the power density of hydraulic hoses and electrical cables is high while that of pneumatic tubes is low. As engineering reasoning, that lets hydraulic power reach a compact actuator through hoses from a power unit located elsewhere, although Kazama notes that the oil in the pipes and return lines is not negligible: oil in the hoses and return circuits decreases the transmittable power.

A practical dividing line, as engineering judgment:

  • Choose electric servo for moderate forces, long strokes with precise profiles, high duty cycles where standby losses add up, and sites where oil leakage is unacceptable.
  • Choose closed-loop hydraulics for very high forces in a small envelope, for shock loads, and for holding a large static force for long periods.
  • Use both, matched axis by axis, under one PLC.

UTEC Industrial integrates VFD and servo drives on Allen-Bradley ControlLogix and CompactLogix controllers, so the actuator choice for each axis does not force a change of control platform. The measured data behind that dividing line are the hydraulic actuator's highest measured forces and the electric system's most consistent response and lowest power draw (Pustavrh et al. 2023, Abstract, Results and Fig. 9; Kazama 2019, Abstract and Conclusion).

Where does valve selection fall in the chain from frame design to monitoring?​

The natural-frequency relation, ω_N² = 2BA²/(VM), is the engineering reason valve performance is decided upstream of the valve. The oil column is only one spring in the load path; the frame, the cylinder mounts, and the pins are springs in series with it. A welded frame that deflects, or relaxes as residual welding stresses redistribute after machining, lowers the effective stiffness and achievable loop bandwidth and can shift the geometry the position transducer was calibrated against. Along the chain:

  • Design and engineering set the moving mass M, the cylinder area A, and the valve location that fixes V.
  • Parts machining, fabrication, and assembly produce the mounts, clevises, and a straight, stiff frame.
  • Weld fatigue and stress relief keep the frame dimensionally stable under the cyclic loads a servo axis applies.
  • Drives, controls, and tuning close the loop inside the stiffness the structure allows.
  • Monitoring watches for the drift that signals contamination, wear, or structural change.

UTEC Industrial stress-relieves and machines welded frames to tolerances of ±0.001 in before assembly, so the structure that carries a closed-loop axis is stable before the loop is tuned. NASA's report notes that its general model allows quick assessment of alternate system hardware or control strategy, which is its use at the design review, before steel is cut (NASA-TM-101644 1990, §2.5 and §5.0).

Related Articles

References​

  • Bosch Rexroth RE 29061/10.05 (2005): 4/2 and 4/3 Proportional Directional Valves, Direct Operated, with Electrical Position Feedback, Types 4WRE and 4WREE. Bosch Rexroth, 2005.
  • NASA NASA-TM-101644 (1990): Simulated Dynamic Response of a Servovalve Controlled Hydraulic Actuator. NASA Langley Research Center, 1990.
  • Lee, K. H., Baek, S. G., Choi, H. R., Moon, H., Ji, S.-H., Koo, J. C. (2019). "Feedforward model-inverse position control of three-stage servo-valve using zero magnitude error tracking control." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 233(7), 2340-2348. DOI 10.1177/0954406218786533
  • Pustavrh, J., Hočevar, M., Podržaj, P., Trajkovski, A., Majdič, F. (2023). "Comparison of hydraulic, pneumatic and electric linear actuation systems." Scientific Reports, 13(1), 20938. DOI 10.1038/s41598-023-47602-x
  • Kazama, T. (2019). "Comparison of power density of transmission elements in hydraulic, pneumatic, and electric drive systems." Mechanical Engineering Letters, 5, 19-00139. DOI 10.1299/mel.19-00139
  • ISO 4406:2021: Hydraulic fluid power — Fluids — Method for coding the level of contamination by solid particles. International Organization for Standardization, 2021.
  • ISO 4413:2010: Hydraulic fluid power — General rules and safety requirements for systems and their components. International Organization for Standardization, 2010.
  • ISO 13849-1:2023: Safety of machinery — Safety-related parts of control systems — Part 1: General principles for design. International Organization for Standardization, 2023.
  • ISO 12100:2010: Safety of machinery — General principles for design — Risk assessment and risk reduction. ISO, 2010.
  • IEC 60204-1:2016+AMD1:2021 CSV (Ed. 6.1): Safety of Machinery -- Electrical Equipment of Machines -- Part 1: General Requirements. International Electrotechnical Commission, 2021.
  • OSHA 29 CFR 1910.147-1989: The Control of Hazardous Energy (Lockout/Tagout). Occupational Safety and Health Administration, 1989.
  • Rockwell Automation 1756-RM094N-EN-P-2025: Logix 5000 Controllers Design Considerations. Rockwell Automation, 2025.

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