A hydraulic potential-based power generation device, control method, and method of use thereof

Abstract

The present application belongs to the technical field of electro-hydraulic control, and particularly relates to a power generation device based on hydraulic potential, a control method and a use method thereof. The present application comprises a hydraulic potential recovery system, a power generation system and an integrated valve group. The hydraulic potential recovery system comprises an accumulator assembly for directly recovering the wasted hydraulic potential in a hydraulic system and a recovery device for recovering the wasted hydraulic potential when the hydraulic cylinder is operating. The oil inlet of the accumulator assembly and the oil outlet of the recovery device are connected to the working port of the integrated valve group, and the oil return port of the accumulator assembly is connected to the oil return port of the integrated valve group. The hydraulic potential recovery system recovers the hydraulic pressure in the external hydraulic system, solving the problem of limited recovery and low recovery rate of the existing recovery system. Meanwhile, the recovered hydraulic potential is converted into electric energy in combination with the integrated valve group and the power generation system, breaking through the traditional hydraulic recovery mode, improving the efficiency and capacity of potential recovery, and greatly improving the utilization rate of the recovered potential.

Description

Technical Field

[0001] This invention belongs to the field of electro-hydraulic control technology, specifically relating to a power generation device, control method, and usage method based on hydraulic potential energy. Background Technology

[0002] With the continuous development of society, hydraulic systems are being used more widely in various industries. Therefore, the question of whether the wasted hydraulic potential energy in traditional hydraulic systems can be recovered and reused has become a hot topic in hydraulic system design and development. Compared with traditional hydraulic systems, hydraulic systems with potential energy recovery are indeed more advantageous. However, with technological advancements, potential energy recovery not only requires the rationality, efficiency, and reliability of the recovery device, but also places high demands on the speed and stability of electrical control.

[0003] Currently, most traditional hydraulic equipment uses accumulators to directly recover the wasted hydraulic potential energy in the hydraulic system. This recovery method has the following main disadvantages:

[0004] 1. An accumulator needs to be added for energy recovery, which also increases the hydraulic pipeline, thereby increasing the risk of system leakage and resulting in low recovery efficiency.

[0005] 2. Limited recovery capacity: When the energy storage capacity of the accumulator reaches its peak, it is no longer possible to recover the wasted potential energy.

[0006] 3. It can easily cause system fluctuations. The system pressure drops during energy recovery and rises after recovery is completed, which reduces the stability of the original system.

[0007] 4. Low recycling rate: The accumulator recovery device only directly recovers the wasted hydraulic potential energy, which is still pressure energy and can only continue to be consumed in the hydraulic system. Summary of the Invention

[0008] The purpose of this invention is to overcome the shortcomings of low hydraulic potential energy recovery rate in existing hydraulic equipment, and to provide a hydraulic potential energy power generation device, control method and usage method with unrestricted hydraulic potential energy recovery and high recovery rate.

[0009] The technical solution adopted by this invention to solve its technical problem is: a hydraulic potential energy power generation device, comprising:

[0010] The hydraulic potential energy recovery system is connected to the high-pressure oil pipeline of the external hydraulic system and is used to recover the hydraulic potential energy of the external hydraulic system.

[0011] A power generation system is connected to the hydraulic potential energy recovery system via an oil circuit to convert the hydraulic potential energy recovered by the hydraulic potential energy recovery system into electrical energy.

[0012] An integrated valve assembly is installed in the hydraulic potential energy recovery system to control the on / off state of the oil circuit;

[0013] The hydraulic potential energy recovery system includes an accumulator assembly for directly recovering the hydraulic potential energy wasted in the hydraulic system and a recoverer for recovering the hydraulic potential energy wasted during the operation of the hydraulic cylinder; the oil inlet of the accumulator assembly and the oil outlet of the recoverer are both connected to the working port of the integrated valve group, and the oil return port of the accumulator assembly is connected to the oil return port of the integrated valve group.

[0014] Furthermore, the energy storage assembly includes:

[0015] The air-filled accumulator pack is connected to the high-pressure oil circuit of the external hydraulic system and is used to store high-pressure oil.

[0016] The first pressure transmitter is connected to the oil circuit of the pneumatic accumulator and is used to detect the pressure in the pneumatic accumulator.

[0017] The first pressure gauge is connected to the oil circuit of the airbag accumulator and is used to directly monitor the pressure in the airbag accumulator.

[0018] An accumulator control valve group is used to control the on / off of the oil circuits between the bladder-type accumulator and the integrated valve group, between the first pressure transmitter and the integrated valve group, and between the first pressure gauge and the integrated valve group.

[0019] Furthermore, the recycler includes,

[0020] A shuttle valve is installed in the oil line between the hydraulic cylinder and the oil inlet of the integrated valve body to realize bidirectional potential energy recovery of the rod-side and rodless sides of the hydraulic cylinder.

[0021] A distributor is located in the oil line between the shuttle valve and the hydraulic cylinder, and is used to aggregate the oil lines of multiple cylinders of the hydraulic cylinder.

[0022] Several recovery check valves are installed in the oil circuit between the cavity of the hydraulic cylinder and the distributor to restrict the direction of oil flow; wherein,

[0023] Several of the recovery check valves are connected to the oil inlet of the distributor, the oil outlet of the distributor is connected to the oil inlet of the shuttle valve, and the oil outlet of the shuttle valve is directly connected to the oil port of the integrated valve assembly.

[0024] Furthermore, the power generation system includes:

[0025] An electro-proportional hydraulic motor converts the pressure energy of the oil transmitted in the hydraulic potential energy recovery system into mechanical energy.

[0026] An alternator is connected to the electro-proportional hydraulic motor via a coupling to convert the mechanical energy output by the electro-proportional hydraulic motor into electrical energy.

[0027] A voltage regulator stabilizes the output voltage of the AC generator within a certain range; wherein,

[0028] The negative output terminal of the AC generator is connected to the negative terminal of the voltage regulator, and the positive output terminal of the AC generator is connected to the positive terminal of the voltage regulator.

[0029] Furthermore, the integrated valve assembly includes:

[0030] A three-position four-way solenoid directional valve is installed in the oil line between the output end of the hydraulic potential energy recovery system and the electro-proportional hydraulic motor, and is used to realize the forward and reverse rotation of the electro-proportional hydraulic motor.

[0031] A ball valve, a second pressure transmitter, a first two-position two-way solenoid directional valve, a second pressure gauge, a first check valve, a direct-acting pressure reducing valve, and a proportional speed control valve are sequentially installed on the oil circuit between the main oil circuit inlet and the three-position four-way solenoid directional valve. The proportional speed control valve controls the flow rate of the oil circuit between the main oil circuit inlet and the three-position four-way solenoid directional valve. The direct-acting pressure reducing valve limits the pressure in its respective oil circuit. The first check valve limits the direction of oil flow in its respective oil circuit. The second pressure gauge visually monitors the real-time pressure of its respective oil circuit. The second pressure transmitter provides control signals to the control system. The ball valve is used to manually open or close its respective oil circuit.

[0032] The second two-position two-way solenoid directional valve is installed in the oil circuit between the three-position four-way solenoid directional valve and the accumulator assembly, and is used to control the opening and closing of the oil circuit.

[0033] The second check valve is located in the oil line between the main oil line outlet and the three-position four-way solenoid directional valve, and is used to restrict the flow direction of the oil in the oil line.

[0034] Furthermore, the inlet P1 of the first two-position two-way solenoid directional valve is connected to the main oil circuit inlet through an internal flow channel; the outlet P2 of the two-position two-way solenoid directional valve is connected to the inlet P of the direct-acting pressure reducing valve through the built-in first check valve; the return port T of the direct-acting pressure reducing valve is connected to the main oil circuit return port T; the outlet A of the direct-acting pressure reducing valve is connected to the inlet P1 of the proportional speed control valve; the outlet P2 of the proportional speed control valve is connected to the inlet P of the three-position four-way solenoid directional valve and the inlet P1 of the first two-position two-way solenoid directional valve; the return port T of the three-position four-way solenoid directional valve is connected to the main oil circuit return port T; and the three-position four-way solenoid directional valve is connected to the inlet and outlet P1 and P2 of the electro-proportional hydraulic motor.

[0035] Furthermore, it also includes a skid and control components for controlling the operation of the control device; wherein,

[0036] The energy storage assembly, power generation system, and control assembly are all fixedly connected to the skid by bolts; the integrated valve group and recovery unit are all fixedly connected to the skid by welding.

[0037] A control method for a power generation device based on hydraulic potential energy includes the following steps:

[0038] S1. Collect initial data, that is, collect the current parameters and status of each system;

[0039] S2. Data filtering, which involves filtering out high-frequency noise and interference signals from the initial data acquired in step S1.

[0040] A low-pass filter is used to remove high-frequency noise and interference signals from the initial data. The filter expression is as follows:

[0041] Where f is the signal frequency, fc is the cutoff frequency, and Hf is the frequency response of the filtered output signal;

[0042] S3. Determine the operating data of each device, that is, determine the working status of each device and whether the power generation system has not been started for a long time;

[0043] S4. Based on the judgment result of step S3, start the operation of each device manually or automatically according to different control types;

[0044] S5. Complete the collection of hydraulic potential energy and its conversion into electrical energy.

[0045] Specifically, whether the power generation system has not been started for a long time in step S3 is as follows: if the power generation system has not been started for a long time, then step P11 is executed; otherwise, step P12 is executed.

[0046] P11. Manually connect the second two-position two-way solenoid directional valve and the third-position four-way solenoid directional valve, so that the high-pressure hydraulic oil in the airbag accumulator enters the electro-proportional hydraulic motor, and then drives the AC generator to generate electricity through the coupling, thereby supplying power to the control system.

[0047] P12. Entering automatic control mode, when the hydraulic cylinder moves, the hydraulic oil pressure increases due to the gravitational potential energy, and then enters the potential energy recovery hydraulic system through the shuttle valve. When the hydraulic cylinder does not move, when the second pressure transmitter on the main oil line of the potential energy recovery hydraulic system detects high-pressure hydraulic oil, it connects the two-position two-way solenoid directional valve. After the high-pressure hydraulic oil is reduced and limited by the direct-acting pressure reducing valve and the proportional speed control valve, it enters the three-position four-way solenoid directional valve and drives the electro-proportional hydraulic motor to rotate. Then, it drives the AC generator to generate electricity through the coupling, and then supplies power to the control system.

[0048] A method for using a power generation device based on hydraulic potential energy, characterized by comprising the following steps:

[0049] L1. Equipment adjustment, which means increasing or decreasing the number of recovery ports on the distributor according to the actual number of hydraulic cylinders on the site;

[0050] L2. Equipment connection: Connect the hydraulic cylinder A and B ports and the main valve inlet P of the field equipment to the recovery interface of the power generation system.

[0051] L3. Potential energy recovery, which means that the control system recovers the wasted hydraulic potential energy through the hydraulic potential energy recovery system according to the equipment parameters;

[0052] L4. Potential energy is converted into electrical energy, that is, the control system converts the potential energy recovered in L3 into electrical energy through the power generation system according to the equipment parameters;

[0053] The power for the hydraulic potential energy recovery system and the power generation system is provided by the power generation system.

[0054] The beneficial effects of the power generation device based on hydraulic potential energy of the present invention are:

[0055] The hydraulic potential energy recovery system recovers hydraulic pressure from an external hydraulic system. Equipped with an accumulator assembly and a recovery unit, this system recovers both wasted hydraulic potential energy from the hydraulic system and hydraulic potential energy wasted during cylinder operation, solving the problems of limited recovery and low recovery rate in existing systems. Furthermore, by integrating an integrated valve assembly and a power generation system, the recovered hydraulic potential energy is converted into electrical energy for use or storage, breaking through the traditional hydraulic recovery method. This not only improves the efficiency and capacity of potential energy recovery but also greatly enhances the utilization rate of the recovered potential energy. Attached Figure Description

[0056] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0057] Figure 1 This is a schematic diagram of the overall structure of the power generation device of the present invention;

[0058] Figure 2 This is a schematic diagram showing the connection between the hydraulic potential energy recovery system and the integrated valve group in an embodiment of the present invention;

[0059] Figure 3 This is the electrical schematic diagram of the power generation system of the present invention;

[0060] Figure 4 This is a control flowchart of the power generation device of the present invention;

[0061] Figure 5 This is a wiring diagram of each component of the electronic control system of the present invention;

[0062] Figure 6 This is a partial structural diagram of the power generation device of the present invention;

[0063] Figure 7 This is a schematic diagram of the overall assembly of the integrated valve assembly of the present invention;

[0064] Figure 8 This is a diagram showing the oil port distribution of the integrated valve assembly of the present invention;

[0065] Figure 9 This is a schematic diagram of the external shape of the energy storage component of the power generation device of the present invention;

[0066] Figure 10 This is a layout diagram of the electrical control system of the power generation device of the present invention;

[0067] Figure 11 This is a schematic diagram of the distributor of the power generation device of the present invention;

[0068] Figure 12 This is a schematic diagram of the skid frame of the power generation device of the present invention;

[0069] Figure 13 This is a flowchart illustrating the control system steps of the power generation device of the present invention;

[0070] Figure 14 This is a control flowchart of the power generation device of the present invention;

[0071] Figure 15 This is a block diagram of the control system of the power generation device of the present invention;

[0072] Figure 16 This is a flowchart of the control method for the power generation device of the present invention;

[0073] Figure 17This is a schematic diagram illustrating an excavator application example of the power generation device of the present invention;

[0074] Figure 18 This is a schematic diagram illustrating an application example of the power generation device of the present invention using a concrete pump truck.

[0075] In the diagram: 1. Hydraulic potential energy recovery system; 11. Accumulator assembly; 111. Pneumatic accumulator pack; 112. First pressure transmitter; 113. First pressure gauge; 114. Accumulator pack control valve assembly; 12. Recoverer; 121. Shuttle valve; 122. Distributor; 123. Recovery check valve; 2. Power generation system; 21. Electro-proportional hydraulic motor; 22. Alternator; 23. Voltage regulator; 3. Integrated valve assembly; 31. Three-position four-way solenoid directional valve; 32. Ball valve; 33. Second... 35. Pressure transmitter, 36. First two-position two-way solenoid directional valve, 37. Second pressure gauge, 38. First check valve, 39. Direct-acting pressure reducing valve, 30. Proportional speed control valve, 310. Second two-position two-way solenoid directional valve, 311. Second check valve, 4. Control components, 41. Circuit breaker, 42. Switching power supply, 43. Lighting, 44. Controller, 45. Terminal block, 46. Intermediate relay, 47. Indicator light, 48. Touch screen, 49. Battery, 410. Button, 5. Skid. Detailed Implementation

[0076] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the invention, and therefore only show the components relevant to the invention.

[0077] like Figures 1-12 The present invention provides a specific embodiment of a power generation device based on hydraulic potential energy, which includes a hydraulic potential energy recovery system 1 connected to a high-pressure oil pipeline of an external hydraulic system for recovering hydraulic potential energy from the external hydraulic system.

[0078] The power generation system 2 is connected to the hydraulic potential energy recovery system 1 by an oil circuit, and is used to convert the hydraulic potential energy recovered by the hydraulic potential energy recovery system 1 into electrical energy.

[0079] Integrated valve assembly 3 is installed in hydraulic potential energy recovery system 1 to control the on / off state of the oil circuit;

[0080] The hydraulic potential energy recovery system 1 includes an accumulator assembly 11 for directly recovering the hydraulic potential energy wasted in the hydraulic system and a recoverer 12 for recovering the hydraulic potential energy wasted during the operation of the hydraulic cylinder; the oil inlet of the accumulator assembly 11 and the oil outlet of the recoverer 12 are both connected to the working port of the integrated valve group 3, and the oil return port of the accumulator assembly 11 is connected to the oil return port of the integrated valve group 3.

[0081] This invention's hydraulic system uses an integrated valve assembly 3 instead of pipe connections, reducing pipe connection points and leakage points. This not only makes the hydraulic potential energy recovery system 1 more compact and reduces costs, but also improves the reliability and safety of the hydraulic system. Furthermore, the hydraulic potential energy recovery system 1, in conjunction with the integrated valve assembly 3, has excellent operability, which is beneficial for the control system to perform precise and automated control, thus making the equipment more efficient, reliable, and intelligent. This invention utilizes a power generation system 2 to convert hydraulic potential energy into electrical energy for recovery, breaking through the traditional hydraulic recovery method. This not only improves the efficiency and capacity of potential energy recovery, but also greatly increases the utilization rate of the recovered potential energy.

[0082] like Figure 2 , 8 As shown in Figures 9 and 1, the energy storage assembly 11 in this embodiment includes:

[0083] The airbag accumulator package 111 is connected to the high-pressure oil circuit of the external hydraulic system and is used to store high-pressure oil.

[0084] The first pressure transmitter 112 is connected to the oil circuit of the pneumatic accumulator 111 and is used to detect the pressure in the pneumatic accumulator 111.

[0085] The first pressure gauge 113 is connected to the oil circuit of the airbag accumulator 111 and is used to directly monitor the pressure in the airbag accumulator 111.

[0086] The accumulator control valve group 114 is used to control the opening and closing of the oil circuit between the airbag accumulator 111 and the integrated valve group 3, between the first pressure transmitter 112 and the integrated valve group 3, and between the first pressure gauge 113 and the integrated valve group 3.

[0087] As one implementation method, the recycler 12 in this embodiment includes,

[0088] The shuttle valve 121 is installed in the oil line between the hydraulic cylinder and the oil inlet of the integrated valve body, and is used to realize bidirectional potential energy recovery of the rod chamber and rodless chamber of the hydraulic cylinder;

[0089] Distributor 122 is located in the oil line between shuttle valve 121 and hydraulic cylinder, and is used to combine the oil lines of multiple cylinders of hydraulic cylinder;

[0090] Several recovery check valves 123 are installed in the oil line between the cavity of the hydraulic cylinder and the distributor 122 to restrict the direction of oil flow; wherein, several recovery check valves 123 are all connected to the oil inlet of the distributor 122, the oil outlet of the distributor 122 is connected to the oil inlet of the shuttle valve 121, and the oil outlet of the shuttle valve 121 is directly connected to the oil port of the integrated valve group 3.

[0091] Hydraulic potential energy recovery system 1 recovers hydraulic pressure from the external hydraulic system. This system includes an accumulator assembly 11 and a recoverer 12, recovering both wasted hydraulic potential energy from the hydraulic system and hydraulic potential energy wasted during cylinder operation. This solves the problems of limited recovery and low recovery rate in existing recovery systems. One branch of the high-pressure oil pipeline from the external hydraulic system is directly connected to a ball valve 32 on the main oil inlet pipeline of the power generation system 2. Simultaneously, several branches of the hydraulic cylinder pipeline from the external hydraulic system are also connected to several recovery check valves 123 on the distributor 122 of the power generation system 2. In this embodiment, there are four recovery check valves 123. See details below. Figure 2 The return oil line of the power generation system 2 flows through the first check valve 37 and then merges into the return oil line of the external hydraulic system, flowing back to the oil tank. This not only greatly reduces the piping layout of the hydraulic system of the power generation unit and lowers costs, but also makes the equipment lightweight, convenient, widely applicable, and highly recyclable.

[0092] like Figure 3 As shown, the power generation system 2 in this embodiment includes:

[0093] The electro-proportional hydraulic motor 21 converts the pressure energy of the oil transmitted in the hydraulic potential energy recovery system 1 into mechanical energy.

[0094] The alternator 22 is connected to the electro-proportional hydraulic motor 21 via a coupling, converting the mechanical energy output by the electro-proportional hydraulic motor 21 into electrical energy.

[0095] The voltage regulator 23 stabilizes the output voltage of the alternator 22 within a certain range; where,

[0096] The negative output terminal of the alternator 22 is connected to the negative terminal of the voltage regulator 23, and the positive output terminal of the alternator 22 is connected to the positive terminal of the voltage regulator 23.

[0097] like Figure 2 As shown, in this embodiment, the integrated valve group 3 includes: a three-position four-way solenoid directional valve 31, which is set in the oil line between the output end of the hydraulic potential energy recovery system 1 and the electro-proportional hydraulic motor 21, and is used to realize the forward and reverse rotation of the electro-proportional hydraulic motor 21.

[0098] The following components are sequentially installed on the oil circuit between the main oil circuit inlet and the three-position four-way solenoid directional valve 31: ball valve 32, second pressure transmitter 33, first two-position two-way solenoid directional valve 35, second pressure gauge 36, first check valve 37, direct-acting pressure reducing valve 38, and proportional speed control valve 39. The proportional speed control valve 39 controls the flow rate of the oil circuit between the main oil circuit inlet and the three-position four-way solenoid directional valve 31; the direct-acting pressure reducing valve 38 limits the pressure in its respective oil circuit; the first check valve 37 limits the direction of oil flow in its respective oil circuit; the pressure gauge visually monitors the real-time pressure of its respective oil circuit; the second pressure transmitter 33 provides control signals to the control system; and the ball valve 32 is used to manually open or close its respective oil circuit.

[0099] The second two-position two-way solenoid directional valve 310 is installed in the oil circuit between the three-position four-way solenoid directional valve 31 and the accumulator assembly 11, and is used to control the opening and closing of the oil circuit.

[0100] The second check valve 311 is located in the oil line between the main oil line outlet and the three-position four-way solenoid directional valve 31, and is used to restrict the direction of oil flow in the oil line.

[0101] Specifically, the first pressure transmitter 112 and the first pressure gauge 113 are mounted on the integrated valve assembly 32. The main inlet of the integrated valve assembly 3 is equipped with a ball valve 32, a second pressure transmitter 33, and a second pressure gauge 36. The inlet P1 of the two-position two-way solenoid directional valve is connected to the main inlet of the integrated valve assembly 3 through an internal flow channel. The outlet P2 of the two-position two-way solenoid directional valve is connected to the inlet P of the direct-acting pressure reducing valve 38 through the internal flow channel of the integrated valve assembly 3 and the built-in first check valve 37. The return port T of the direct-acting pressure reducing valve 38 is connected to the return port T of the integrated valve assembly 3 through the internal flow channel of the integrated valve assembly 3. The outlet of the direct-acting pressure reducing valve 38... A is connected to the inlet P1 of the proportional speed control valve 39 through the internal flow channel of the integrated valve group 3. The outlet P2 of the proportional speed control valve 39 is connected to the inlet P of the three-position four-way solenoid directional valve 31 and the inlet P1 of the second two-position two-way solenoid directional valve 310 through the internal flow channel of the integrated valve group 3. The return port T of the three-position four-way solenoid directional valve 31 is connected to the return port T of the integrated valve group 3 through the internal flow channel of the integrated valve group 3. The three-position four-way solenoid directional valve 31 is connected to the inlet and outlet P1 and P2 of the electro-proportional hydraulic motor 21 through the working ports A and B of the integrated valve group 3. A second check valve 311 is also installed on the return line of the integrated valve group 3.

[0102] This embodiment also includes a skid 5 and a control component 4 for controlling the operation of the device; the accumulator assembly 11, the power generation system 2, and the control component 4 are all fixedly connected to the skid 5 by bolts; the integrated valve assembly 3 and the recovery unit 12 are fixedly connected to the skid 5 by welding. The skid 5 serves as the supporting base for the entire device. The accumulator assembly 11 is fixed to the left side of the skid 5 by bolts. The integrated valve assembly 3 is directly welded to the internal suspension beam of the skid 5 using a cantilever beam. The recovery unit 12 is welded to the bottom platform of the skid 5. The power generation system 2 is connected to the connecting plate on the skid 5 by bolts. The control component 4 is placed directly on the upper platform of the skid 5 and secured with bolts. The remaining hydraulic pipes are fixed to the skid 5 with pipe clamps to complete the connection with the corresponding components.

[0103] The control component 4, directly mounted on the skid 5, is used to control the hydraulic potential energy recovery system 1 to recover hydraulic potential energy from the external hydraulic system; to control the power generation system 2 to convert the hydraulic potential energy recovered by the hydraulic potential energy recovery system 1 into electrical energy; and to control the on / off state of each valve in the integrated valve group 3. For example... Figure 5 As shown, in one implementation, the control system is directly mounted on the skid 5. The control system includes a switching power supply 42, a circuit breaker 41, a lighting lamp 43, a controller 44 (Programmable Logic Controller 44, PLC), terminal blocks 45, intermediate relays 46, indicator lights 47, a touch screen 48, and a battery 49. Specifically, the positive wire of the circuit breaker 41 and the positive wire of the battery 49 are connected in parallel to the positive wire of the alternator 22; the positive wire of the switching power supply 42 and the positive wire of the lighting lamp 43 are connected in parallel to the negative wire of the circuit breaker 41; and the negative wire of the switching power supply 42 and the negative wire of the lighting lamp 43 are connected in parallel to the negative wire of the alternator 22. The 24V output port and 0V output port of the switching power supply 42 are connected to the L and M ports of the PLC controller 44, respectively. Button 410 is connected to the PLC controller 44. The digital input terminals of the PLC controller 44 are connected to the first pressure transmitter 112 and the second pressure transmitter 33. The input terminal of the intermediate relay 46 is connected to the digital output terminal of the PLC controller 44 via the terminal block 45. The analog output terminal of the PLC controller 44 is connected to the coil of the proportional speed control valve 39 and the coil of the electro-proportional hydraulic motor 21 via the terminal block 45. The indicator light 47 is connected to the digital output terminal of the PLC controller 44 via the terminal block 45. The output terminal of the intermediate relay 46 is connected to the coil of the first two-position two-way solenoid valve 35, the coil of the three-position four-way solenoid valve 31, and the coil of the second two-position two-way solenoid valve 310. The touch screen 48 communicates with the PLC controller 44 via RS485.

[0104] Control methods for power generation devices based on hydraulic potential energy, such as Figures 13 to 15 As shown, it includes the following steps:

[0105] S1. Collect initial data, that is, collect the current parameters and status of each system;

[0106] S2. Data filtering, that is, filtering out high-frequency noise and interference signals in the initial data collected in step S1, processing the original current value of the hydraulic motor through a low-pass filter, and sending the signal to the controller 44 to form feedforward control; using a current sensor to detect the voltage value output by the generator, and then processing it through a low-pass filter before sending the signal to the controller 44 to form feedback control.

[0107] S3. Determine the operating data of each device, that is, determine the working status of each device and whether the power generation system 2 has not been started for a long time; in step S3, whether the power generation system 2 has not been started for a long time is specifically: if the power generation system 2 has not been started for a long time, then execute step P11; otherwise, execute step P12.

[0108] P11. Manually connect the second two-position two-way solenoid directional valve 310 and the three-position four-way solenoid directional valve 31, so that the high-pressure hydraulic oil in the airbag accumulator 111 enters the electro-proportional hydraulic motor 21, and then drives the alternator 22 to generate electricity through the coupling, which in turn supplies power to the control system. In this embodiment, it specifically supplies power to the control cabinet and the battery 49.

[0109] P12. Entering automatic control mode, when the hydraulic cylinder moves, the hydraulic oil pressure increases due to gravitational potential energy, and then enters the potential energy recovery hydraulic system through shuttle valve 121. When the hydraulic cylinder does not move, when the second pressure transmitter 33 on the main oil line of the potential energy recovery hydraulic system detects high-pressure hydraulic oil, it connects the two-position two-way solenoid directional valve. After the high-pressure hydraulic oil is reduced and limited by the direct-acting pressure reducing valve 38 and the proportional speed control valve 39, it enters the three-position four-way solenoid directional valve 31 and drives the electro-proportional hydraulic motor 21 to rotate. Then, it drives the alternator 22 to generate electricity through the coupling, which then powers the control system. In this embodiment, it powers the control cabinet and the battery 49. When the second pressure transmitter 33 fails, the above operation can also be performed through the operation button 410 on the control cabinet panel, which will not be described in detail here.

[0110] S4. Based on the judgment result of step S3, start the operation of each device manually or automatically according to different control types;

[0111] S5. Complete the collection of hydraulic potential energy and its conversion into electrical energy.

[0112] In this embodiment, the data filtering in step S2 uses a low-pass filter to filter out high-frequency noise and eliminate interference signals in signal acquisition, so that the acquired signal has better stability and accuracy.

[0113] The expression for the low-pass filter is:

[0114] Where f is the signal frequency, fc is the cutoff frequency, and Hf is the frequency response of the filtered output signal.

[0115] It should be further explained that in step S4, the different control types include three response processes of controller 44, specifically as follows:

[0116] The first control response process: Based on the signal from the main inlet oil pressure sensor, the controller 44 sends an on command to the first and second two-position two-way solenoid directional valves 310 and the left position of the three-position four-way solenoid directional valve 31.

[0117] The second control response process: Based on the accumulator pressure signal, determine whether to increase or decrease the proportional current of the hydraulic motor. When the accumulator pressure is low, decrease the proportional current of the hydraulic motor; otherwise, increase the proportional current of the hydraulic motor.

[0118] The third control response process: The feedback signal from the current sensor of the battery 49, the feedforward signal of the electro-proportional hydraulic motor 21, and all energy consumption information are integrated. The deviation between the expected value and the actual value of the output voltage is compared and transmitted to the controller 44. After the tracking differentiator in the ADRC active disturbance rejection control algorithm outputs a transition signal to track the target signal, thereby avoiding excessive error that leads to excessively long tracking time or overshoot. Then, the feedback signal, feedback differential signal, transition signal, and target differential signal output by the extended state observer are nonlinearly integrated to obtain the preliminary output of the controller 44. Then, the disturbance control signal of the extended state observer is superimposed on the preliminary output of the controller 44 and divided by the controller 44 gain of the system to obtain the final controller 44 output.

[0119] The transfer function expression of the tracking differentiator in this embodiment is:

[0120]

[0121] Where S is the Laplace transform of the function under initial conditions with respect to time t, and T is the result of the Laplace transform of the function. 1、 T2 is the time constant, and V is the original signal.

[0122] If we make T2 in the above formula infinitely close to T1, then the tracking differentiator is equivalent to the product of a pure differentiating element S and a second-order system double-pole filter. This can reduce the amplification effect of noise and make the control system more sensitive to changes in the input signal.

[0123] The expression for the extended state observer:

[0124] The state-space model is used to describe the dynamic behavior of a system, reflecting the relationship between the system's state and time.

[0125] Based on the above-mentioned method of using the power generation device, such as Figure 16 As shown, it includes the following steps:

[0126] L1. Equipment adjustment, i.e., according to the actual number of hydraulic cylinders on the equipment on site, increase or decrease the recovery interface on the distributor 122;

[0127] L2. Equipment connection: Connect the hydraulic cylinder A and B ports and the main valve inlet P of the field equipment to the recovery interface of the power generation system 2.

[0128] L3. Potential energy recovery, that is, the control system recovers the wasted hydraulic potential energy through the hydraulic potential energy recovery system 1 according to the equipment parameters;

[0129] L4. Potential energy is converted into electrical energy, that is, the control system converts the potential energy recovered in L3 into electrical energy through the power generation system 2 according to the equipment parameters;

[0130] The hydraulic potential energy recovery system 1 and the power generation system 2 are powered by the power generation system 2. All energy-consuming components in the hydraulic potential energy recovery system 1 are powered by its own 49 sets of batteries. In addition, the hydraulic potential energy recovery system 1 also provides 24V power to other equipment.

[0131] The power generation device in this embodiment is feasible and widely applicable. Under the combined action of the power generation system 2 and the integrated valve group 3, the hydraulic potential energy recovered in the hydraulic potential energy recovery system 1 is converted into electrical energy and applied to applications such as… Figure 17 excavators and such Figure 18 In practical applications, excavators and concrete pump trucks that combine the aforementioned power generation devices have the following advantages:

[0132] 1. Energy saving and emission reduction: Hydraulic potential energy recovery can reduce the consumption of oil in the hydraulic system, thereby reducing the energy consumption of excavators or concrete pump trucks and achieving the goal of energy saving and emission reduction.

[0133] 2. Improved efficiency: Hydraulic potential energy recovery can make fuller use of the power of excavators or concrete pump trucks during operation, thereby improving work efficiency.

[0134] 3. Extended lifespan: Hydraulic potential energy recovery can reduce the working pressure and temperature of the hydraulic system, extending the service life of hydraulic components.

[0135] 4. Reduced failures: Hydraulic potential energy recovery can reduce the workload and operating pressure of the hydraulic system, lower the system failure rate, and reduce maintenance costs.

[0136] 5. Increased safety: Hydraulic potential energy recovery can reduce the energy consumption of excavators or concrete pump trucks during operation and reduce the release of kinetic energy, thereby increasing the safety of excavators or concrete pump trucks.

[0137] It should be understood that the specific embodiments described above are for illustrative purposes only and are not intended to limit the scope of the invention. Obvious variations or modifications derived from the spirit of the invention are still within the protection scope of the invention.

Claims

1. A power generation device based on hydraulic potential energy, characterized in that, include: The hydraulic potential energy recovery system (1) is connected to the high-pressure oil pipeline of the external hydraulic system and is used to recover the hydraulic potential energy of the external hydraulic system. The power generation system (2) is connected to the hydraulic potential energy recovery system (1) by oil circuit, and is used to convert the hydraulic potential energy recovered by the hydraulic potential energy recovery system (1) into electrical energy. An integrated valve assembly (3) is installed in the hydraulic potential energy recovery system (1) to control the opening and closing of the oil circuit; The hydraulic potential energy recovery system (1) includes an accumulator assembly (11) for directly recovering the hydraulic potential energy wasted in the hydraulic system and a recoverer (12) for recovering the hydraulic potential energy wasted during the operation of the hydraulic cylinder; the oil inlet of the accumulator assembly (11) and the oil outlet of the recoverer (12) are both connected to the working port of the integrated valve group (3), and the oil return port of the accumulator assembly (11) is connected to the oil return port of the integrated valve group (3); The energy storage assembly (11) includes: The airbag accumulator pack (111) is connected to the high-pressure oil circuit of the external hydraulic system and is used to store high-pressure oil; The first pressure transmitter (112) is connected to the oil circuit of the pneumatic accumulator (111) and is used to detect the pressure in the pneumatic accumulator (111). The first pressure gauge (113) is connected to the oil circuit of the airbag accumulator (111) and is used to directly monitor the pressure in the airbag accumulator (111); Accumulator pack control valve group (114) is used to control the opening and closing of the oil circuit between the airbag accumulator pack (111) and the integrated valve group (3), between the first pressure transmitter (112) and the integrated valve group (3), and between the first pressure gauge (113) and the integrated valve group (3). The recycler (12) includes: A shuttle valve (121) is installed in the oil line between the hydraulic cylinder and the oil inlet of the integrated valve group (3) to realize bidirectional potential energy recovery of the rod chamber and rodless chamber of the hydraulic cylinder; A distributor (122) is provided on the oil line between the shuttle valve (121) and the hydraulic cylinder, and is used to aggregate the oil lines of the multiple cylinders of the hydraulic cylinder; Several recovery check valves (123) are disposed in the oil line between the cavity of the hydraulic cylinder and the distributor (122) to restrict the direction of oil flow; wherein, Several of the recovery check valves (123) are connected to the oil inlet of the distributor (122), the oil outlet of the distributor (122) is connected to the oil inlet of the shuttle valve (121), and the oil outlet of the shuttle valve (121) is directly connected to the oil port of the integrated valve group (3).

2. The power generation device based on hydraulic potential energy according to claim 1, characterized in that, The power generation system (2) includes: An electro-proportional hydraulic motor (21) converts the pressure energy of the oil transmitted in the hydraulic potential energy recovery system (1) into mechanical energy; An alternator (22) is connected to the electro-proportional hydraulic motor (21) via a coupling, and converts the mechanical energy output by the electro-proportional hydraulic motor (21) into electrical energy. The voltage regulator (23) stabilizes the voltage output by the alternator (22) within a certain range; wherein, The negative output terminal of the alternator (22) is connected to the negative terminal of the voltage regulator (23), and the positive output terminal of the alternator (22) is connected to the positive terminal of the voltage regulator (23).

3. The power generation device based on hydraulic potential energy according to claim 2, characterized in that, The integrated valve assembly (3) includes: A three-position four-way solenoid directional valve (31) is installed in the oil line between the output end of the hydraulic potential energy recovery system (1) and the electro-proportional hydraulic motor (21) to realize the forward and reverse rotation of the electro-proportional hydraulic motor (21); A ball valve (32), a second pressure transmitter (33), a first two-position two-way solenoid directional valve (35), a second pressure gauge (36), a first check valve (37), a direct-acting pressure reducing valve (38), and a proportional speed control valve (39) are sequentially installed on the oil circuit between the main oil circuit inlet and the three-position four-way solenoid directional valve (31). The proportional speed control valve (39) is used to control the flow rate of the oil circuit between the main oil circuit inlet and the three-position four-way solenoid directional valve (31). The direct-acting pressure reducing valve (38) is used to limit the pressure of the oil circuit. The first check valve (37) is used to limit the direction of oil flow in the oil circuit. The second pressure gauge (36) is used to visually monitor the real-time pressure of the oil circuit. The second pressure transmitter (33) provides control signals to the control system. The ball valve (32) is used to manually open or close the oil circuit. The second two-position two-way solenoid directional valve (310) is located in the oil line between the three-position four-way solenoid directional valve (31) and the accumulator assembly (11) and is used to control the opening and closing of the oil line. The second check valve (311) is located on the oil line between the main oil line return port and the three-position four-way solenoid directional valve (31) to restrict the direction of oil flow in the oil line.

4. A power generation device based on hydraulic potential energy according to claim 3, characterized in that, The inlet P1 of the first two-position two-way solenoid directional valve (35) is connected to the main oil circuit inlet through an internal flow channel. The outlet P2 of the first two-position two-way solenoid directional valve (35) is connected to the inlet P of the direct-acting pressure reducing valve (38) through the built-in first check valve (37). The return port T of the direct-acting pressure reducing valve (38) is connected to the main oil circuit return port T. The outlet A of the direct-acting pressure reducing valve (38) is connected to the proportional speed control valve. The oil inlet P1 of (39) is connected, the oil outlet P2 of the proportional speed control valve (39) is connected to the oil inlet P of the three-position four-way solenoid directional valve (31) and the oil inlet P1 of the second two-position two-way solenoid directional valve (310), the oil return port T of the three-position four-way solenoid directional valve (31) is connected to the oil return port T of the main oil circuit, and the three-position four-way solenoid directional valve (31) is connected to the inlet and outlet P1 and P2 of the electro-proportional hydraulic motor (21).

5. A power generation device based on hydraulic potential energy according to claim 4, characterized in that, It also includes a skid (5) and a control assembly (4) for controlling the operation of the device; wherein, The energy storage assembly (11), the power generation system (2), and the control assembly (4) are all fixedly connected to the skid frame (5) by bolts; the integrated valve group (3) and the recovery unit (12) are all fixedly connected to the skid frame (5) by welding.

6. The control method for a power generation device based on hydraulic potential energy according to claim 5, characterized in that, Includes the following steps: S1. Collect initial data, that is, collect the current parameters and status of each system; S2. Data filtering, which involves filtering out high-frequency noise and interference signals from the initial data acquired in step S1. A low-pass filter is used to remove high-frequency noise and interference signals from the initial data. The filter expression is as follows: ； Where f is the signal frequency. The cutoff frequency, This refers to the frequency response of the filtered output signal. S3. Determine the operating data of each device, that is, determine the working status of each device and whether the power generation system (2) has not been started for a long time; S4. Based on the judgment result of step S3, start the operation of each device manually or automatically according to different control types; S5. Complete the collection of hydraulic potential energy and its conversion into electrical energy.

7. The control method for a power generation device based on hydraulic potential energy according to claim 6, characterized in that, Whether the power generation system (2) has not been started for a long time in step S3 is specifically: if the power generation system (2) has not been started for a long time, then step P11 is executed; otherwise, step P12 is executed. P11. Manually connect the second two-position two-way solenoid directional valve (310) and the three-position four-way solenoid directional valve (31) so that the high-pressure hydraulic oil in the airbag accumulator (111) enters the electro-proportional hydraulic motor (21), and then drives the alternator (22) to generate electricity through the coupling, thereby supplying power to the control system. P12. Entering automatic control mode, that is, when the hydraulic cylinder moves, the hydraulic oil pressure increases due to the support of gravitational potential energy, and then enters the hydraulic potential energy recovery system (1) through the shuttle valve (121). When the hydraulic cylinder does not move, when the second pressure transmitter (33) on the main oil line of the hydraulic potential energy recovery system (1) detects high pressure hydraulic oil, it connects the first two-position two-way solenoid directional valve (35). After the high pressure hydraulic oil is reduced and limited by the direct-acting pressure reducing valve (38) and the proportional speed regulating valve (39), it enters the three-position four-way solenoid directional valve (31) and drives the electro-proportional hydraulic motor (21) to rotate. Then, it drives the alternator (22) to generate electricity through the coupling, and then supplies power to the control system.

8. The method of using a power generation device based on hydraulic potential energy according to claim 4, characterized in that, Includes the following steps: L1. Equipment adjustment, that is, according to the actual number of hydraulic cylinders of the equipment on site, increase or decrease the recovery interface on the distributor (122); L2. Equipment connection: Connect the hydraulic cylinder A and B ports and the main valve inlet P of the field equipment to the recovery interface of the power generation system (2); L3. Potential energy recovery, that is, the control system recovers the wasted hydraulic potential energy through the hydraulic potential energy recovery system (1) according to the equipment parameters; L4. Potential energy is converted into electrical energy, that is, the control system converts the potential energy recovered in L3 into electrical energy through the power generation system (2) according to the equipment parameters; The power for the hydraulic potential energy recovery system (1) and the power generation system (2) is provided by the power generation system (2).

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