In this study, a new compressible flow model for small orifice openings in pneumatic proportional directional control valves has been proposed. It is crucial to precisely control pneumatic valves over all control ranges; yet, conventional flow models fail around the closed position of the valve. The main deficit of the existing studies in the literature is to assume constant values for the parameters of the flow model over changing operating conditions. It has been demonstrated that these rough assumptions are insufficient in precisely predicting the mass flow rate, particularly for small orifice openings. An enhanced experimental setup has been introduced to improve the effectiveness of the proposed model. The cracking pressure ratio and parameters of the model have been identified with experimental method. In the proposed model, new empirical coefficients have been established after a thorough investigation of the impact of supply pressure on the flow behavior of the valve. Validation studies of the model in both the filling and exhausting states of the valve have been carried out at various supply pressures and orifice openings, yielding rather promising modeling performances. In validation tests, the real pressure and the pressure produced by new model have been compared, and good agreement has been achieved with 0.0039% absolute error. According to the findings, the proposed improved flow model can be selected in precision pneumatic control applications.
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