Electrical control device for high pressure protection in hydraulic control systems

Abstract

The application discloses an electrical control device for high-pressure protection in a hydraulic control system and relates to the technical field of hydraulic control, which comprises a high-pressure detection module, which is used for monitoring pressure data of a hydraulic system in real time and transmitting the pressure data to a control processing core via an analog quantity input module. The application adopts double-channel independent control logic through a redundant protection unit. Even if a single loop fails, another loop can still independently execute a safety instruction to eliminate the risk of single-point failure. Meanwhile, an intelligent control unit realizes advanced and accurate pressure regulation and trend suppression by means of a high-frequency response electro-hydraulic servo valve and a proportional valve and relies on bus communication, so that high-pressure risks are eliminated in the budding state, and a leap from passive response to active protection is realized. Furthermore, high system integration and intelligent management are realized through an intelligent valve island, wiring is simplified, remote monitoring and diagnosis are supported, and the maintenance performance is improved.

Description

Technical Field

[0001] This invention relates to the field of hydraulic control technology, specifically to an electrical control device for high-pressure protection in a hydraulic control system. Background Technology

[0002] Hydraulic control systems are widely used in various industrial fields such as metallurgy, engineering machinery, mining equipment, and aerospace due to their significant advantages such as high power density, fast response speed, high control precision, and ease of realizing linear motion. The working performance and reliability of hydraulic systems are directly related to the operating efficiency and safety of the entire equipment. In hydraulic systems, pressure is one of the most critical parameters. Excessive system pressure is a major cause of failure. It not only accelerates the wear of hydraulic components, shortens the life of seals, and causes oil overheating, but more seriously, it can lead to catastrophic consequences such as oil pipe rupture and actuator malfunction, causing equipment damage or even personal injury.

[0003] The existing electrical control devices for high-pressure protection in hydraulic control systems have the following defects:

[0004] 1. Patent document CN200942721Y discloses an electrical control hydraulic system device for dump trucks. However, the electrical control hydraulic system device in the above document adopts a single control circuit or protection mechanism. Once a key component fails, the entire system will lose its protection function, resulting in a technical problem of safety hazards. Summary of the Invention

[0005] The purpose of this invention is to provide an electrical control device for high-pressure protection in a hydraulic control system, so as to solve the technical problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: an electrical control device for high-pressure protection in a hydraulic control system, comprising:

[0007] The high-pressure detection module monitors the pressure data of the hydraulic system in real time and transmits it to the control processing core via the analog input module. The control processing core establishes bidirectional data connections with the high-pressure detection module, the redundant protection unit, the intelligent control unit, and the hydraulic actuator through the data bus.

[0008] The redundant protection unit includes a first solenoid valve control circuit and a second solenoid valve control circuit connected in parallel using dual-channel independent control logic, and the control signals of the two circuits are independently generated from different output ports of the control processing core.

[0009] The intelligent control unit integrates a high-frequency electro-hydraulic servo valve and a proportional valve, and establishes bus communication with the control processing core through an intelligent valve island.

[0010] The hydraulic actuator includes a high-pressure, high-flow hydraulic pump and a hydraulic motor, and is connected to various control valves via hydraulic pipelines.

[0011] Preferably, the high-pressure detection module includes several pressure sensors installed at key nodes of the hydraulic system, and transmits data to the control processing core simultaneously in the following two ways:

[0012] Real-time pressure values ​​are transmitted via the analog input module;

[0013] The pressure over-limit alarm signal is transmitted through the digital input module;

[0014] The pressure sensors are redundantly arranged at key nodes.

[0015] Preferably, the control processing core specifically adopts a programmable logic controller (PLC) that internally stores a pressure protection algorithm program. This program processes pressure sensor signals in real time, and when the system pressure value is detected to exceed a set threshold, it coordinates control in the following ways:

[0016] Send commands to the intelligent control unit to adjust the opening degree of the high-frequency electro-hydraulic servo valve and the proportional valve;

[0017] Start the first and second solenoid valve control circuits in the redundant protection unit;

[0018] Start the hydraulic actuator to adjust the operating status of the high-pressure, high-flow hydraulic pump.

[0019] Preferably, the pressure protection algorithm program employs a multi-level protection strategy, including:

[0020] Level 1 protection: When the pressure reaches the warning value, the control processing core adjusts the opening of the proportional valve through the intelligent control unit to reduce the system pressure;

[0021] Secondary protection: When the pressure continues to rise to the dangerous value and the primary protection fails to effectively suppress the pressure rise, the control processing core activates the first solenoid valve control circuit and the second solenoid valve control circuit of the redundant protection unit.

[0022] Level 3 protection: When the pressure reaches the emergency shutdown value, the control processing core cuts off the power supply to the high-pressure, high-flow hydraulic pump and opens the pressure relief circuit.

[0023] Preferably, the redundant protection unit includes a first solenoid valve and a second solenoid valve arranged in parallel, and a differential pressure hydraulic directional valve. The left control chamber of the differential pressure hydraulic directional valve is directly connected to the hydraulic oil source, and the right control chamber is connected to the hydraulic oil source through the parallel oil circuit of the first solenoid valve and the second solenoid valve. The first solenoid valve and the second solenoid valve are controlled by independent output channels of the control processing core, and are configured to open the oil circuit to maintain the pressure of the right control chamber when energized, and to cut off the oil circuit to release pressure when de-energized. The pressure difference between the left control chamber and the right control chamber is used to push the valve core to switch to the protection position.

[0024] Preferably, the hydraulic pipeline is equipped with a safety valve and an accumulator, wherein the set pressure of the safety valve is higher than the rated working pressure of the system and lower than the emergency shutdown threshold of the three-level protection.

[0025] Preferably, it also includes a human-machine interface that is connected to the control processing core to display system pressure data, alarm information and equipment status in real time, and allows operators to set pressure protection thresholds and manually activate redundant protection units.

[0026] Preferably, the control processing core is also connected to a historical data storage module, which records the occurrence time, duration and pressure peak of pressure over-limit events in real time, and supports data export through a communication interface.

[0027] Preferably, the pressure relief circuit includes a normally closed electromagnetic pressure relief valve and a manual pressure relief valve, and the normally closed electromagnetic pressure relief valve and the manual pressure relief valve are connected in parallel between the main hydraulic circuit and the oil tank. The normally closed electromagnetic pressure relief valve is controlled to open by the control processing core when the three-level protection is triggered.

[0028] Preferably, the operating steps of the electrical control device for high-pressure protection in this hydraulic control system are as follows:

[0029] S1. Multiple pressure sensors in the high-pressure detection module continuously collect pressure data from key nodes of the hydraulic system. The collected pressure signals are transmitted to the control processing core in parallel through two paths. The continuous real-time pressure values ​​are transmitted via the analog input module for the control processing core to perform precise calculations and monitoring. When the pressure instantly exceeds a certain preset limit, the sensor or independent switch transmits an emergency switch alarm signal through the digital input module, providing a fast response channel.

[0030] S2. The control and processing core runs the built-in pressure protection algorithm program, analyzes the received pressure data in real time, compares the real-time pressure value with the preset multi-level protection threshold, and makes intelligent judgments based on the rate and trend of pressure rise.

[0031] S3. The system automatically triggers the corresponding protection level based on the degree of pressure exceeding the limit:

[0032] Level 1 protection: When the system pressure reaches or exceeds the warning value, the control processing core sends a command to the intelligent control unit. The intelligent control unit drives the intelligent valve island through the bus to precisely adjust the opening of the proportional valve, fine-tuning the system pressure and smoothly returning it to the normal range. This stage aims to eliminate pressure fluctuations without interrupting system operation.

[0033] Level 2 protection: If the pressure continues to rise to the dangerous value, or if the Level 1 protection fails to effectively reduce the pressure within a certain period of time, the control processing core immediately activates the redundant protection unit. The control processing core controls the first solenoid valve control circuit and the second solenoid valve control circuit through two independent output ports respectively. The first and second solenoid valves of the two circuits are simultaneously de-energized. After the solenoid valves are de-energized, the parallel oil circuit is cut off, causing the right control chamber of the differential pressure hydraulic directional valve to depressurize. At this time, the pressure in the left control chamber is much greater than the pressure in the right control chamber. The pressure difference pushes the valve core to move rapidly, switching to the protection position, and guiding the high-pressure oil in the main oil circuit back to the oil tank to achieve rapid pressure relief.

[0034] Level 3 protection: When the pressure reaches the highest emergency shutdown value, it indicates that the system is facing extreme danger. The control processing core executes the highest level protection command, immediately cuts off the power to the high-pressure, high-flow hydraulic pump, stops pumping hydraulic oil, and at the same time controls the normally closed electromagnetic pressure relief valve to open, forming the largest pressure relief channel. It is connected in parallel with the manual pressure relief valve to ensure that the system pressure can be released quickly and completely.

[0035] S4. Throughout the process, the human-machine interface displays the system pressure curve, alarm information, currently triggered protection level and status of each device in real time. The operator can manually set the pressure threshold, view historical alarm records, or manually activate the redundant protection unit or pressure relief circuit when necessary.

[0036] S5, the historical data storage module will record in detail the occurrence time, duration, peak pressure reached, and protective actions taken by the system for each pressure over-limit event. This data can be exported through the communication interface for subsequent fault analysis, system optimization, and preventive maintenance.

[0037] Compared with the prior art, the beneficial effects of the present invention are:

[0038] 1. This invention employs a dual-channel independent control logic through a redundant protection unit. Even if one loop fails, the other loop can still independently execute safety commands, eliminating the risk of single-point failure. At the same time, the intelligent control unit uses high-frequency electro-hydraulic servo valves and proportional valves, and relies on bus communication to achieve advanced and precise pressure regulation and trend suppression, eliminating high-pressure risks in their infancy. This represents a leap from passive response to active protection. Furthermore, high system integration and intelligent management are achieved through an intelligent valve island, simplifying wiring while supporting remote monitoring and diagnostics, which enhances maintainability.

[0039] 2. This invention enhances monitoring reliability by redundantly arranging pressure sensors at key nodes and enables sensor self-diagnosis through data cross-comparison, effectively avoiding false alarms. The signal transmission adopts a dual-path parallel mechanism of analog and digital signals. The analog channel provides high-precision pressure data to support intelligent trend analysis and precise control, while the digital channel achieves millisecond-level high-speed response to over-limit signals, gaining valuable time for safety decisions. The historical data storage module connected to the control processing core records the time, duration, and peak data of each pressure over-limit event in detail, providing data support for system fault root cause analysis, process optimization, and predictive maintenance.

[0040] 3. This invention achieves intelligent and gradient active pressure management through a multi-level collaborative protection strategy built around a programmable logic controller. The first-level protection adjusts the opening of the proportional valve through the intelligent control unit to attempt to restore pressure in a fine and gentle manner. If this fails, the second-level protection is activated, triggering a redundant dual solenoid valve control circuit for strong intervention. Finally, if the pressure reaches the emergency shutdown value, the third-level protection will immediately cut off the power supply to the high-pressure, high-flow hydraulic pump and open the automatic pressure relief circuit. This ensures safety while maximizing production continuity. In addition, a parallel electromagnetic and manual dual pressure relief valve is set up, so that even in the extreme case of complete failure of the control system, pressure can still be forcibly relieved by mechanical manual means, providing safety redundancy.

[0041] 4. This invention constructs redundant protection based on pure hydraulic logic by using a differential pressure hydraulic directional valve and parallel dual solenoid valves. The dual solenoid valves adopt a fail-safe design with energized maintenance and de-energized protection. The system can be maintained as long as either solenoid valve is energized normally. Protection is only triggered when both valves fail simultaneously. This ensures safety while improving system availability. The differential pressure hydraulic directional valve directly drives the valve core to switch via hydraulic differential pressure. Even if the control system fails completely, it can still provide reliable protection. The safety valve installed on the hydraulic pipeline serves as a mechanical overload protection layer to cope with instantaneous high-pressure impacts on the system. The accumulator effectively absorbs pressure pulsations, smooths system pressure, provides a stable environment for electronic control, and also has an emergency power function. Attached Figure Description

[0042] Figure 1 This is a schematic diagram of the process of pressure monitoring and multi-level protection according to the present invention;

[0043] Figure 2 This is a schematic diagram of the overall workflow structure of the present invention;

[0044] Figure 3 This is a schematic diagram of the hydraulic process of the redundant protection unit of the present invention;

[0045] Figure 4This is a schematic diagram of the three-stage protection pressure relief circuit of the present invention;

[0046] Figure 5 This is a schematic diagram illustrating the physical connection relationship between the oil source, the actuator, and the key protection element of the present invention.

[0047] Figure 6 This is a schematic diagram of the working steps of the present invention.

[0048] In the diagram: 1. High-pressure detection module; 2. Analog input module; 3. Control processing core; 4. Redundancy protection unit; 5. Intelligent control unit; 6. Hydraulic actuator; 7. First solenoid valve control circuit; 8. Second solenoid valve control circuit; 9. High-frequency electro-hydraulic servo valve; 10. Proportional valve; 11. Intelligent valve island; 12. High-pressure, high-flow hydraulic pump; 13. Hydraulic motor; 15. Pressure sensor; 17. Digital input module; 18. Pressure relief circuit; 19. First solenoid valve; 20. Second solenoid valve; 21. Differential pressure hydraulic directional valve; 22. Left control chamber; 23. Hydraulic oil source; 24. Right control chamber; 25. Safety valve; 26. Accumulator; 27. Human-machine interface; 28. Historical data storage module; 29. ​​Normally closed solenoid pressure relief valve; 30. Manual pressure relief valve. Detailed Implementation

[0049] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0050] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "front end," "rear end," "both ends," "one end," and "the other end," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0051] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0052] Please see Figure 1 , Figure 2 and Figure 5 The present invention provides an embodiment of an electrical control device for high-pressure protection in a hydraulic control system, comprising: a high-pressure detection module 1, which monitors the pressure data of the hydraulic system in real time and transmits it to the control processing core 3 via an analog input module 2; the control processing core 3 establishes bidirectional data connections with the high-pressure detection module 1, the redundant protection unit 4, the intelligent control unit 5, and the hydraulic actuator 6 via a data bus; the redundant protection unit 4 includes a first solenoid valve control circuit 7 and a second solenoid valve control circuit 8 connected in parallel using dual-channel independent control logic, and the control signals of the two circuits are independently derived from different output ports of the control processing core 3; the intelligent control unit 5 integrates a high-frequency electro-hydraulic servo valve 9 and a proportional valve 10, and establishes bus communication with the control processing core 3 through an intelligent valve island 11; the hydraulic actuator 6 includes a high-pressure, high-flow hydraulic pump 12 and a hydraulic motor 13, and is connected to each control valve via hydraulic pipelines.

[0053] Furthermore, the redundant protection unit 4 adopts a dual-channel independent control logic with a first solenoid valve control loop 7 and a second solenoid valve control loop 8. This allows the other loop to still independently receive instructions from the control processing core 3 and perform safe pressure relief or shutdown operations even if one loop fails completely due to a fault. This avoids the risk of system loss of control due to single-point failure. At the same time, the control signals of the two loops come from different output ports of the control core, which avoids common-cause failures of the signal source from the source and further enhances safety.

[0054] The high-pressure detection module 1 acquires data in real time through the analog input module 2 to ensure high accuracy and speed of pressure monitoring. The control processing core 3 can quickly obtain the system pressure status. The intelligent control unit 5 integrates the high-frequency electro-hydraulic servo valve 9 and the proportional valve 10, which communicate with the control core at high speed through the bus. This enables the system to not only react to pressure exceeding the limit, but also to make intelligent predictions and fine adjustments based on real-time pressure trends. In this way, the opening of the proportional valve 10 or the high-frequency electro-hydraulic servo valve 9 can be finely adjusted in advance before the pressure reaches the dangerous threshold, so as to smoothly control the flow and pressure, avoid drastic pressure fluctuations or frequent start-stop pressure relief, and eliminate high pressure danger in the early stage.

[0055] By setting up the intelligent valve island 11, valve island technology can greatly simplify the electrical connection of complex hydraulic circuits, reduce wiring work and fault points. At the same time, the intelligent valve island 11 supports bus communication, allowing centralized configuration, status monitoring and fault diagnosis of all valves in the intelligent control unit 5, which greatly improves the maintainability and intelligence level of the system.

[0056] The high-pressure, high-flow hydraulic pump 12 and hydraulic motor 13 in the hydraulic actuator 6 can ensure that the power output is precisely matched with the load demand. Furthermore, through the precise adjustment of the intelligent control unit 5, unnecessary overflow loss and unloading loss can be avoided, allowing the system to operate in the high-efficiency range, thereby achieving energy-saving effects.

[0057] Based on intelligent predictive proactive control and the smooth adjustment capability of high-frequency electro-hydraulic servo valve 9 and proportional valve 10, the hydraulic shock caused by sudden depressurization or start-up of the system can be significantly reduced, protecting hydraulic pipelines, seals and actuators, and extending service life.

[0058] Please see Figure 1 , Figure 2 and Figure 5 The present invention provides an embodiment of an electrical control device for high-pressure protection in a hydraulic control system. The high-pressure detection module 1 includes several pressure sensors 15 installed at key nodes of the hydraulic system, and transmits data to the control processing core 3 simultaneously in the following two ways: transmitting real-time pressure values ​​through an analog input module 2 and transmitting pressure over-limit alarm signals through a digital input module 17. The pressure sensors 15 are redundantly arranged at key nodes. The control processing core 3 is also connected to a historical data storage module 28, which records the occurrence time, duration, and pressure peak value of pressure over-limit events in real time, and supports data export through a communication interface.

[0059] Furthermore, by redundantly arranging multiple pressure sensors 15 at key nodes, sensor self-diagnosis can be achieved through cross-comparison of data. When the data of one sensor is seriously inconsistent with other sensors or system logic, a sensor fault alarm can be triggered, avoiding system malfunctions caused by false alarms or failures of a single sensor, thereby enhancing the reliability of monitoring.

[0060] Analog input channel: Transmits continuous real-time pressure values, providing high-precision pressure data for the control processing core 3, which is used for intelligent trend analysis, proportional regulation and closed-loop control, and is the foundation for achieving refined and forward-looking control;

[0061] Digital input channel: Directly transmits over-limit alarm signals of switch quantities. This path has an extremely fast response speed and can be directly scanned by the control processing core 3 and triggered to trigger the highest priority interrupt service routine, ensuring instantaneous response to dangerous pressures and buying valuable time for safety decisions.

[0062] The historical data storage module 28 records the data of each pressure over-limit event, providing data for subsequent root cause analysis and system optimization. This allows for analysis of whether the overpressure is an occasional event or a frequent problem, and judgment of its correlation with specific production actions. This enables targeted improvements to processes or maintenance of equipment. By analyzing historical pressure trends, the performance degradation of components can be predicted, and maintenance can be arranged in advance before complete failure, avoiding unplanned downtime.

[0063] All of the above functions together construct a multi-layered security architecture:

[0064] First layer: Intelligent predictive control based on high-precision analog data;

[0065] The second layer: ultra-high-speed hardware response based on digital alarm signals;

[0066] The third layer: redundantly arranged sensors and dual solenoid valve circuits ensure that any single point of failure will not cause the system protection function to be lost.

[0067] The fourth layer: Historical data recording function is used for continuous improvement, to prevent similar events from happening again, and to improve the long-term reliability of the system.

[0068] Please see Figure 1 , Figure 2 , Figure 4 and Figure 5This invention provides an embodiment of an electrical control device for high-pressure protection in a hydraulic control system. The control processing core 3 specifically employs a programmable logic controller (PLC) internally storing a pressure protection algorithm program. This program processes the signal from the pressure sensor 15 in real time. When the system pressure value exceeds a set threshold, it coordinates control in the following ways: sending instructions to the intelligent control unit 5 to adjust the opening of the high-frequency electro-hydraulic servo valve 9 and the proportional valve 10; activating the first solenoid valve control circuit 7 and the second solenoid valve control circuit 8 in the redundant protection unit 4; and activating the hydraulic actuator 6 to adjust the operating state of the high-pressure, high-flow hydraulic pump 12. The pressure protection algorithm program employs a multi-level protection strategy, including: Level 1 protection: when the pressure reaches a warning value, the control... The control processing core 3 reduces system pressure by adjusting the opening of the proportional valve 10 through the intelligent control unit 5. Secondary protection: When the pressure continues to rise to the dangerous value and the primary protection fails to effectively suppress the pressure rise, the control processing core 3 activates the first solenoid valve control circuit 7 and the second solenoid valve control circuit 8 of the redundant protection unit 4. Tertiary protection: When the pressure reaches the emergency shutdown value, the control processing core 3 cuts off the power supply to the high-pressure, high-flow hydraulic pump 12 and opens the pressure relief circuit 18. The pressure relief circuit 18 includes a normally closed solenoid pressure relief valve 29 and a manual pressure relief valve 30. The normally closed solenoid pressure relief valve 29 and the manual pressure relief valve 30 are connected in parallel between the main hydraulic circuit and the oil tank. The normally closed solenoid pressure relief valve 29 is controlled to open by the control processing core 3 when the tertiary protection is triggered.

[0069] Furthermore, by using a programmable logic controller (PLC) and a pressure protection algorithm program, with the PLC as the control core, the system possesses high flexibility and customizability. Users can easily adjust the pressure thresholds and protection logic at each level by modifying the program to adapt to different working conditions and equipment requirements. Moreover, the system adopts a step-by-step progressive response method, which can avoid the decrease in production efficiency and equipment damage caused by directly triggering the highest level of protection regardless of the degree of pressure exceeding the limit.

[0070] Level 1 protection: Based on the precise electro-hydraulic proportional technology of the intelligent control unit 5, it achieves smooth and fine adjustment of pressure, aiming to restore the system pressure to the normal range in the event of slight disturbances and avoid triggering higher-level protection.

[0071] Secondary protection: When primary protection fails, redundant solenoid valve circuits are activated, ensuring absolute reliability of safe operation through redundant hard-wired circuits, providing a solid intermediate barrier for the system;

[0072] Level 3 protection: As the final safety barrier, it directly cuts off the power source and opens the pressure relief circuit 18 to eliminate the danger in the fastest and most thorough way and prevent catastrophic accidents.

[0073] The normally closed electromagnetic pressure relief valve 29 is automatically controlled by the programmable logic controller and responds quickly. It is a key actuator for realizing three-level protection automation. The manual pressure relief valve 30 serves as a purely mechanical and electrical-independent final safety measure. Even in extreme cases such as complete power failure of the control system, failure of the programmable logic controller, or jamming of the normally closed electromagnetic pressure relief valve 29 itself, the operator can still manually force pressure relief to ensure safety redundancy.

[0074] This device can not only handle slow pressure rises, but also cope with sudden pressure surges. Its multi-level strategy can comprehensively cover various pressure runaway scenarios, from minor anomalies to serious failures, demonstrating strong adaptability and robustness.

[0075] Please see Figure 2 and Figure 3 An embodiment of the present invention provides an electrical control device for high-pressure protection in a hydraulic control system. The redundant protection unit 4 includes a first solenoid valve 19 and a second solenoid valve 20 arranged in parallel, and a differential pressure hydraulic control directional valve 21. The left control chamber 22 of the differential pressure hydraulic control directional valve 21 is directly connected to the hydraulic oil source 23, and the right control chamber 24 is connected to the hydraulic oil source 23 through the parallel oil circuit of the first solenoid valve 19 and the second solenoid valve 20. The first solenoid valve 19 and the second solenoid valve 20 are controlled by the independent output channels of the control processing core 3, and are configured to open the oil circuit to maintain the pressure of the right control chamber 24 when energized, and to cut off the oil circuit to release pressure when de-energized. The pressure difference between the left control chamber 22 and the right control chamber 24 is used to push the valve core to switch to the protection position. A safety valve 25 and an accumulator 26 are provided on the hydraulic pipeline. The set pressure of the safety valve 25 is higher than the rated working pressure of the system and lower than the emergency shutdown threshold of the three-level protection.

[0076] Furthermore, by setting the differential pressure hydraulic control directional valve 21, the switching can be driven directly by the physical quantity of the hydraulic pressure difference between the left and right control chambers 24 without relying on any electronic signals or controller commands. This enables the redundant protection unit 4 to become a hardware-based safety barrier independent of the electronic control system. Even if the control processing core 3 completely fails and shuts down, the hydraulic logic remains effective.

[0077] When the first solenoid valve 19 and the second solenoid valve 20 are configured to be energized, they are turned on to maintain the pressure in the right control chamber 24 and de-energized to release pressure. Thus, when the solenoid valves malfunction, the differential pressure hydraulic control directional valve 21 can be triggered immediately to switch to the protection position, thereby improving the safety of use.

[0078] The two solenoid valves use parallel oil circuits and are controlled by independent channels of the control processing core 3. As long as either solenoid valve is energized normally, it is sufficient to maintain the pressure of the right control chamber 24 and prevent the system from malfunctioning. The protection will only be triggered when both solenoid valves lose power due to failure. This can avoid unplanned system shutdowns caused by the failure of a single component and ensure safety.

[0079] Safety valve 25 acts as a purely mechanical safety barrier. It is set at a pressure higher than the system working pressure but lower than the emergency shutdown threshold of the electronic system. It mainly addresses two scenarios: first, as a final backup when the electronic protection system completely fails; and second, to suppress unavoidable, brief, and severe pressure peaks in the system. It can effectively protect hydraulic lines, actuators, and seals from instantaneous high-pressure damage and extend the system life.

[0080] Accumulator 26 can quickly absorb hydraulic shocks caused by flow pulsations of the high-pressure, high-flow hydraulic pump 12 or sudden start-stop or reversal of the actuator, smoothing system pressure, providing a more stable adjustment environment for the electronic control system, reducing the effect of false trigger protection, and under pressure holding conditions, accumulator 26 can compensate for minor system leaks, helping to maintain pressure stability and reducing the frequency of start-ups of the high-pressure, high-flow hydraulic pump 12. In extreme cases, if the power source fails, the pressure oil stored in accumulator 26 can be used as emergency power, increasing safety in use.

[0081] Please see Figure 2 An embodiment of the present invention provides an electrical control device for high-pressure protection in a hydraulic control system, which further includes a human-machine interface 27 and is communicatively connected to the control processing core 3. The human-machine interface 27 displays system pressure data, alarm information and equipment status in real time, and allows operators to set pressure protection thresholds and manually start redundant protection units 4. The control processing core 3 is also connected to a historical data storage module 28, which records the occurrence time, duration and pressure peak of pressure over-limit events in real time, and supports data export through the communication interface.

[0082] Furthermore, the human-machine interface 27 and the historical data storage module 28 of the hydraulic control system's high-pressure protection device together constitute a complete monitoring and data analysis system, significantly improving the system's operability and maintainability. The human-machine interface 27 displays system pressure, alarm information, and equipment status in real time, providing operators with an intuitive panoramic view of system operation. It also allows for flexible setting of pressure protection thresholds and manual activation of redundant protection units 4, greatly enhancing the system's control flexibility and emergency response capabilities. The historical data storage module 28 records in detail the occurrence time, duration, and pressure peak of each pressure over-limit event, forming a complete pressure record. This provides data support for fault tracing, performance analysis, and preventive maintenance. Data export is supported through the communication interface, facilitating in-depth data analysis and maintenance report generation. This enables a shift from a passive response to an active prediction maintenance mode, thereby giving the system modern industrial characteristics of transparent status, user-friendly operation, and data-driven management, significantly reducing the difficulty of operation and maintenance and professional dependence.

[0083] Please see Figure 6 The present invention provides an embodiment of an electrical control device for high-pressure protection in a hydraulic control system. The working steps of the electrical control device for high-pressure protection in the hydraulic control system are as follows:

[0084] S1. Multiple pressure sensors 15 in the high-pressure detection module 1 continuously collect pressure data from key nodes of the hydraulic system. The collected pressure signals are transmitted to the control processing core 3 in parallel through two paths. The continuous real-time pressure values ​​are transmitted via the analog input module 2 for the control processing core 3 to perform precise calculations and monitoring. When the pressure instantly exceeds a certain preset limit, the sensor or independent switch transmits an emergency switch alarm signal through the digital input module 17 to provide a fast response channel.

[0085] S2, the control and processing core 3 runs the built-in pressure protection algorithm program, analyzes the received pressure data in real time, compares the real-time pressure value with the preset multi-level protection threshold, and makes intelligent judgments based on the rate and trend of pressure rise.

[0086] S3. The system automatically triggers the corresponding protection level based on the degree of pressure exceeding the limit:

[0087] Level 1 protection: When the system pressure reaches or exceeds the warning value, the control processing core 3 sends a command to the intelligent control unit 5. The intelligent control unit 5 drives the intelligent valve island 11 through the bus to precisely adjust the opening of the proportional valve 10, and fine-tune the system pressure to smoothly return to the normal range. This stage aims to eliminate pressure fluctuations without interrupting the system operation.

[0088] Secondary protection: If the pressure continues to rise to the dangerous value, or if the primary protection fails to effectively reduce the pressure within a certain period of time, the control processing core 3 immediately activates the redundant protection unit 4. The control processing core 3 controls the first solenoid valve control circuit 7 and the second solenoid valve control circuit 8 through two independent output ports respectively. The first solenoid valve 19 and the second solenoid valve 20 of the two circuits are simultaneously de-energized. After the solenoid valves are de-energized, the parallel oil circuit is cut off, causing the right control chamber 24 of the differential pressure hydraulic control directional valve 21 to depressurize. At this time, the pressure of the left control chamber 22 is much greater than the pressure of the right control chamber 24. The pressure difference pushes the valve core to move rapidly, switch to the protection position, and guide the high-pressure oil of the main oil circuit back to the oil tank to achieve rapid pressure relief.

[0089] Level 3 protection: When the pressure reaches the highest emergency shutdown value, it indicates that the system is facing extreme danger. The control processing core 3 executes the highest level protection command, immediately cuts off the power to the high-pressure, high-flow hydraulic pump 12, stops pumping hydraulic oil, and at the same time controls the normally closed electromagnetic pressure relief valve 29 to open, forming the largest pressure relief channel, which is connected in parallel with the manual pressure relief valve 30 to ensure that the system pressure can be released quickly and completely.

[0090] S4. Throughout the process, the human-machine interface 27 displays the system pressure curve, alarm information, currently triggered protection level and status of each device in real time. The operator can manually set the pressure threshold, view historical alarm records, or manually activate the redundant protection unit 4 or the pressure relief circuit 18 when necessary.

[0091] S5 and the historical data storage module 28 will record in detail the occurrence time, duration, peak pressure reached, and protective actions taken by the system for each pressure over-limit event. This data can be exported through the communication interface for subsequent fault analysis, system optimization, and preventive maintenance.

[0092] The working principle utilizes a dual-channel independent control logic through the redundant protection unit 4. Even if one loop fails, the other loop can still independently execute safety commands, eliminating the risk of single-point failure. Simultaneously, the intelligent control unit 5, through the high-frequency electro-hydraulic servo valve 9 and the proportional valve 10, and relying on bus communication, achieves proactive and precise pressure regulation and trend suppression, eliminating high-pressure risks at their inception. This represents a leap from passive response to active protection. Furthermore, high-level system integration and intelligent management are achieved through the intelligent valve island 11, simplifying wiring while supporting remote monitoring and diagnostics, thus enhancing maintainability. By redundantly arranging the pressure sensors 15 at key nodes, it not only enhances… To enhance monitoring reliability, the system enables sensor self-diagnosis through data cross-comparison, effectively avoiding false alarms. Signal transmission employs a dual-path parallel mechanism of analog and digital signals. The analog channel provides high-precision pressure data, supporting intelligent trend analysis and precise control, while the digital channel achieves millisecond-level high-speed response to over-limit signals, gaining valuable time for safety decisions. The historical data storage module 28 connected to the control processing core 3 records the time, duration, and peak data of each pressure over-limit event in detail, providing data support for system fault root cause analysis, process optimization, and predictive maintenance. Through a multi-level collaborative protection strategy built around a programmable logic controller, intelligent and tiered protection is achieved. The system employs a multi-level active pressure management system. Level 1 protection adjusts the opening of proportional valve 10 via intelligent control unit 5 to attempt pressure recovery in a gentle and precise manner. If this fails, Level 2 protection is activated, triggering a redundant dual solenoid valve control circuit for forceful intervention. Ultimately, if the pressure reaches the emergency shutdown threshold, Level 3 protection immediately cuts off the power to the high-pressure, high-flow hydraulic pump 12 and activates the automatic pressure relief circuit 18. This ensures safety while maximizing production continuity. Parallel solenoid and manual dual pressure relief valves are also included, providing safety redundancy even in extreme situations where the control system completely fails, allowing for forced pressure relief via mechanical manual means. A differential pressure hydraulic directional valve 21 further facilitates this process. The system employs a parallel dual solenoid valve system, creating redundant protection based on pure hydraulic logic. The dual solenoid valves feature a fail-safe design with energized maintenance and de-energized protection. The system can be maintained as long as either solenoid valve is energized, and protection is only triggered when both valves fail simultaneously. This ensures safety while improving system availability. The differential pressure hydraulic control directional valve 21 directly drives the valve core to switch via the hydraulic differential pressure, providing reliable protection even if the control system fails completely. The safety valve 25 installed on the hydraulic line serves as a mechanical overload protection layer to cope with instantaneous high-pressure impacts on the system. The accumulator 26 effectively absorbs pressure pulsations, smooths system pressure, provides a stable environment for electronic control, and also has an emergency power function.

[0093] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. An electrical control device for high-pressure protection in a hydraulic control system, characterized in that: include: The high pressure detection module (1) monitors the pressure data of the hydraulic system in real time and transmits it to the control processing core (3) via the analog input module (2). The control processing core (3) establishes bidirectional data connections with the high pressure detection module (1), the redundant protection unit (4), the intelligent control unit (5) and the hydraulic actuator (6) respectively via the data bus. The redundant protection unit (4) includes a first solenoid valve control loop (7) and a second solenoid valve control loop (8) connected in parallel using dual-channel independent control logic, and the control signals of the two loops are independently from different output ports of the control processing core (3). The intelligent control unit (5) integrates a high-frequency electro-hydraulic servo valve (9) and a proportional valve (10), and establishes bus communication with the control processing core (3) through the intelligent valve island (11); The hydraulic actuator (6) includes a high-pressure, high-flow hydraulic pump (12) and a hydraulic motor (13), and is connected to each control valve through hydraulic pipelines; The high-pressure detection module (1) includes several pressure sensors (15) installed at key nodes of the hydraulic system, and transmits data to the control processing core (3) simultaneously in the following two ways: Real-time pressure values ​​are transmitted via the analog input module (2); The pressure over-limit alarm signal is transmitted through the digital input module (17); The pressure sensors (15) are redundantly arranged at key nodes; The control processing core (3) specifically adopts a programmable logic controller, which internally stores a pressure protection algorithm program. This program processes the pressure sensor (15) signal in real time. When the system pressure value is detected to exceed the set threshold, it coordinates control in the following ways: Send commands to the intelligent control unit (5) to adjust the opening of the high-frequency electro-hydraulic servo valve (9) and the proportional valve (10); Start the first solenoid valve control circuit (7) and the second solenoid valve control circuit (8) in the redundant protection unit (4); Start the hydraulic actuator (6) to adjust the operating status of the high-pressure, high-flow hydraulic pump (12); The pressure protection algorithm program employs a multi-level protection strategy, including: Level 1 protection: When the pressure reaches the warning value, the control processing core (3) adjusts the opening of the proportional valve (10) through the intelligent control unit (5) to reduce the system pressure; Secondary protection: When the pressure continues to rise to the dangerous value and the primary protection fails to effectively suppress the pressure rise, the control processing core (3) activates the first solenoid valve control circuit (7) and the second solenoid valve control circuit (8) of the redundant protection unit (4). Level 3 protection: When the pressure reaches the emergency shutdown value, the control processing core (3) cuts off the power supply to the high-pressure high-flow hydraulic pump (12) and opens the pressure relief circuit (18).

2. The electrical control device for high-pressure protection in a hydraulic control system according to claim 1, characterized in that: The redundant protection unit (4) includes a first solenoid valve (19) and a second solenoid valve (20) arranged in parallel, as well as a differential pressure hydraulic control directional valve (21). The left control chamber (22) of the differential pressure hydraulic control directional valve (21) is directly connected to the hydraulic oil source (23), and the right control chamber (24) is connected to the hydraulic oil source (23) through the parallel oil circuit of the first solenoid valve (19) and the second solenoid valve (20). The first solenoid valve (19) and the second solenoid valve (20) are controlled by the independent output channels of the control processing core (3), and are configured to open the oil circuit to maintain the pressure of the right control chamber (24) when energized, and cut off the oil circuit to release pressure when de-energized. The pressure difference between the left control chamber (22) and the right control chamber (24) is used to push the valve core to switch to the protection position.

3. The electrical control device for high-pressure protection in a hydraulic control system according to claim 1, characterized in that: The hydraulic pipeline is equipped with a safety valve (25) and an accumulator (26). The set pressure of the safety valve (25) is higher than the rated working pressure of the system and lower than the emergency shutdown threshold of the three-level protection.

4. The electrical control device for high-pressure protection in a hydraulic control system according to claim 1, characterized in that: It also includes a human-machine interface (27) and is connected to the control processing core (3) to display system pressure data, alarm information and equipment status in real time, and allows operators to set pressure protection thresholds and manually start redundant protection units (4).

5. The electrical control device for high-pressure protection in a hydraulic control system according to claim 1, characterized in that: The control processing core (3) is also connected to a historical data storage module (28). The historical data storage module (28) records the occurrence time, duration and pressure peak of the pressure over-limit event in real time, and supports data export through the communication interface.

6. The electrical control device for high-pressure protection in a hydraulic control system according to claim 1, characterized in that: The pressure relief circuit (18) includes a normally closed electromagnetic pressure relief valve (29) and a manual pressure relief valve (30), and the normally closed electromagnetic pressure relief valve (29) and the manual pressure relief valve (30) are connected in parallel between the main hydraulic circuit and the oil tank. The normally closed electromagnetic pressure relief valve (29) is controlled to open by the control processing core (3) when the third-level protection is triggered.

7. The method of using the electrical control device for high-pressure protection in a hydraulic control system according to claim 6, characterized in that, The operating steps of the electrical control device for high-pressure protection in this hydraulic control system are as follows: S1, High pressure detection module (1) continuously monitors the pressure value of the main pipeline of the hydraulic system. The monitored pressure analog signal is converted into a digital signal through analog input module (2). The digital pressure signal is transmitted to the control processing core (3) in real time through the data bus. S2, the control processing core (3) compares the received real-time pressure value with the internally preset multi-level pressure thresholds, and executes the corresponding multi-level protection strategy based on the comparison result: Level 1 protection: When the system pressure reaches or exceeds the warning value, but is below the danger value, the control processing core (3) sends a command to the intelligent control unit (5) through the bus. The intelligent control unit (5) drives the proportional valve (10) to adjust the opening and slowly reduce the system pressure. The high pressure situation is eliminated through fine control. Secondary protection: If the pressure continues to rise to the dangerous value or the primary protection fails to bring the pressure back to the safe range within a certain period of time, the control processing core (3) immediately starts the redundant protection unit (4) and sends an opening command to the first solenoid valve control circuit (7) and the second solenoid valve control circuit (8). The dual-circuit solenoid valves act simultaneously to quickly unload or cut off the pressure source, providing double insurance to prevent protection failure due to a single circuit failure. Level 3 protection: When the pressure reaches the highest emergency shutdown value, it indicates that the system is extremely dangerous. The first two levels of protection have failed or are insufficient to suppress the pressure surge. The control processing core (3) executes the highest level of protection command, immediately cuts off the power supply of the high-pressure high-flow hydraulic pump (12), stops the power source, and at the same time triggers the normally closed electromagnetic pressure relief valve (29) in the pressure relief circuit (18) to open, so that the main hydraulic pipeline is connected to the oil tank, and performs forced rapid pressure relief to quickly reduce the system pressure to a safe level. S3. After the entire protection process or any level of action, the control processing core (3) continues to monitor pressure changes through the high-pressure detection module (1). When the pressure returns to normal and stabilizes, the control processing core (3) can only be manually reset after the operator confirms that the fault has been eliminated. Even in the extreme case of complete power failure of the control system, mechanical emergency pressure relief can still be performed by operating the manual pressure relief valve (30) to ensure safe use.

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