Apparatus for regulating kaplan type hydraulic machine

Abstract

The Kaplan machine includes an impeller with pivotable impeller blades. This invention relates to a device capable of adjusting the angle of attack of the impeller blades. Furthermore, the Kaplan machine includes an adjustable guide. This invention particularly relates to the combined control of the impeller and guide of a hydraulic press. The device according to the invention is characterized by high efficiency and high reliability over long periods.

Description

[0001] This invention relates to a device for controlling a Kaplan-type hydraulic press, also known as a Kaplan machine. The Kaplan machine includes an impeller with pivotable impeller blades. This invention relates to a device by which the angle of attack of the impeller blades can be controlled. Furthermore, the Kaplan machine includes an adjustable guide. This invention particularly relates to the combined control of the impeller and guide of the hydraulic press.

[0002] Traditionally, in Kaplan machines, the energy required to regulate the impeller blades is provided in the form of pressure and volumetric flow rate by a hydraulic accumulator along with a downstream control valve. In this open system, the accumulator pressure is throttled through the opening of the control valve until the necessary volumetric flow rate is achieved for the desired cylinder movement. This technology allows for unrestricted control of both differential and synchronizing cylinders.

[0003] Other devices for controlling hydraulic presses are known in the prior art. For example, document DE 10 2017 106 693B3 discloses such a device, which in principle is also applicable to controlling the impeller of a Kaplan machine. In the disclosed device, a pump unit that operates at a variable speed is used, which is connected to the hydraulic cylinder via an unlockable check valve. However, this presents various difficulties related to the fact that the hydraulic cylinder used to pivot the impeller blades is part of the rotating system of the hydraulic press, while the rest of the equipment is part of the stationary system. To allow the hydraulic fluid (usually oil) used to operate the hydraulic cylinder to enter the rotating system from the stationary system and return, a rotary joint, called an oilhead in hydraulic equipment, is usually provided. The rotary joint typically has a certain internal oil leakage, which is necessary for cooling and lubricating the rotary joint bearings. Depending on the type, the pressure acting on the rotary joint, and the current oil temperature, the internal oil leakage can range from 0.5 to 200 liters / minute. To keep the impeller in place (the most common operating mode, accounting for about 90% of the operating time), continuous adjustment is required to compensate for the drift of the hydraulic cylinder (caused by leakage in the rotary joint).

[0004] If the impeller blade position of the Kaplan machine is controlled using the device disclosed in document DE 10 2017 106 693 B3, different difficulties arise depending on the type of pump used. Using a gear pump is problematic because gear pumps do not allow continuous operation at low speeds, which are necessary to hold the impeller in place. The resulting rapid pump wear precludes this option. If a plunger pump is used, it can operate at low speeds without problems under high pressure during continuous operation. However, the following factors significantly increase losses in this system: Flushing oil must be supplied to the plunger pump for permissible continuous operation. This also means additional continuous losses in the system, in addition to the continuous operation of the additional flushing pump. Furthermore, the unlockable check valve must remain open while the pump is running continuously. Consequently, internal pump leakage from the plunger pump will continue to be stored as further losses.

[0005] The technical problem to be solved by the present invention is to improve the device disclosed in document DE 10 2017 106 693 B3, so that the device can be used efficiently and reliably for a long time to regulate the impeller of the Kaplan machine.

[0006] The aforementioned technical problem is solved by the design scheme according to the independent claim. Other advantageous embodiments of the invention are derived from the dependent claims.

[0007] The invention will now be described with reference to the accompanying drawings. In the drawings:

[0008] Figure 1a The device according to the invention shown in the first embodiment

[0009] Figure 1b The device according to the invention shown in the second embodiment

[0010] Figure 2 The device according to the invention is shown in another embodiment.

[0011] exist Figure 1a The diagram schematically illustrates the structure of a device according to the invention for controlling a Kaplan-type hydraulic press in a first embodiment. This device is used to control the angle of attack of the impeller blades. The device includes a collection and compensation container, indicated by 1; a first pump unit, indicated by 2; a second pump unit, indicated by 3; a storage unit, indicated by 5; and a hydraulic cylinder, indicated by 6. The hydraulic cylinder 6 operates the impeller blade control mechanism (in... Figure 1a(Not shown in the diagram) and is part of a rotating system. The hydraulic cylinder 6 can be configured as a synchronous cylinder or a differential cylinder. In the case of a synchronous cylinder, the areas and volumes of the two cylinder chambers to which pressure is applied are equal, while in the case of a differential cylinder, they are different sizes. In a differential cylinder, the two sides of the cylinder are distinguished. The side where the rod is located is referred to here as the rod side, and the other side as the piston side. The hydraulic cylinder 6 is connected to the rest of the equipment via a swivel joint, indicated by 7. The two pump units 2 and 3 each include a pump driver with a variable speed. Here, the first pump unit 2 is used to control the hydraulic cylinder 6 in a first operating mode, and the second pump unit 3 is used to control the hydraulic cylinder 6 in a second operating mode. The first operating mode is characterized by the impeller blades being moved rapidly. This operating mode typically accounts for about 10% of the total operating time. The second operating mode is characterized by the impeller blades remaining in a fixed position or moving only very slowly. This second operating mode typically accounts for about 90% of the total operating time.

[0012] Figure 1a The device shown is very similar in arrangement (i.e., regarding the first pump assembly 2) to the device known in document DE 10 2017 106 693 B3. Here, the first pump assembly 2 also includes two pumps with reversible delivery directions. Figure 1a In this design, two pumps are arranged on a shaft driven by a variable-speed pump driver connected to the shaft. However, other configurations are also possible; for example, the pumps could be driven by the pump driver via a gearbox. It is even conceivable that the pump driver comprises a motor and a frequency converter for each of the two pumps, respectively. Further description can be found in the references... Figure 1a The embodiment shown. Here, the corresponding interfaces of the pumps are connected to the control lines of the hydraulic cylinder 6, such that in one rotational direction of the shaft, one pump delivers hydraulic fluid towards the hydraulic cylinder 6, while the other pump receives hydraulic fluid from the hydraulic cylinder 6. The opposite is true in the other rotational direction of the shaft. Unlike the device in document DE 10 2017 106 693 B3, in... Figure 1a In this configuration, the rotary joint 7 is positioned between the interface of the hydraulic cylinder 6 and the first pump unit 2. The rotary joint 7 here serves only to transmit power to the rotating system.

[0013] As in the device described in document DE 10 2017 106 693 B3, Figure 1aThe device shown includes two unlockable check valves, denoted as 4.1 and 4.3, and two pilot valves, denoted as 4.2 and 4.4. The right port of the lower pump is connected to the right side of the hydraulic cylinder 6 via the unlockable check valve 4.3, and the left port of the upper pump is connected to the left side of the hydraulic cylinder 6 via the unlockable check valve 4.1. The piping from the first pump assembly 2 to the rotary joint 7 (where the unlockable check valves 4.1 and 4.3 are arranged) is referred to hereinafter as the control piping. The other ports of the pumps are directly connected to the collection and compensation containers 1, respectively. That is, in one direction of rotation of the shaft, the lower pump pumps hydraulic fluid from the collection and compensation containers 1 into the right side of the hydraulic cylinder 6, while the upper pump pumps hydraulic fluid from the left side of the hydraulic cylinder 6 into the collection and compensation containers 1. In the other direction of rotation of the shaft, the volumetric flow rate is reversed. Here, this is on the premise that the check valves 4.1 and 4.3 are unlocked (see the description of the operating state below).

[0014] Unlike the device in document DE 10 2017 106 693 B3, the rotary joint 7 causes a continuous flow of hydraulic fluid into the collection and compensation container 1. The hydraulic fluid required for this (in both operating modes) comes from the collection and compensation container 1 and the storage tank 5, which is connected to one of the control lines. A preferably adjustable throttle valve, denoted 4.9, is arranged between the relevant control line and the storage tank 5. An unlockable check valve, denoted 4.7, is arranged in parallel with the throttle valve 4.9. Similar to check valves 4.1 and 4.3, check valve 4.7 is controlled by a pilot valve, denoted 4.8. In the first operating mode, check valve 4.7 is open, thus throttle valve 4.9 is inactive. In the second operating mode, check valve 4.7 is closed, thus throttle valve 4.9 is active (see the description of the operating states below).

[0015] The shaft of the first pump unit 2 is driven by a variable-speed pump driver capable of operating in both rotational directions. The pump driver typically includes a servo motor powered by a frequency converter. The pump driver of the first pump unit 2 is preferably designed for four-quadrant operation.

[0016] The shaft of the second pump unit 3 is also driven by a variable-speed pump driver that can operate in both rotational directions. The pump driver typically includes a servo motor, which is electrically powered by a frequency converter. The pump driver of the second pump unit 3 is preferably designed for two-quadrant operation.

[0017] The shaft of the second pump unit 3 is connected to only one pump. One port of this pump is connected to the collection and compensation container 1, and the other port is connected to the control line. Here, the pipeline of the second pump unit 3 leads to the control line that is not connected to the memory 5. The pipeline from the second pump unit 3 to the relevant control line is referred to below as the pressure line. The connection between the pressure line and the relevant control line is also located at the associated unlockable check valve (…). Figure 1a - Between check valve 4.1) and rotary joint 7. An unlockable check valve, denoted 4.13, is arranged in the pressure line. Check valve 4.13 is controlled by a pilot valve, denoted 4.14. Optionally, the pressure line and the control line connected thereto are connected to the collection and compensation container 1 via a throttle valve and a two-position three-way directional valve. The throttle valve is denoted 4.12, and the two-position three-way directional valve is denoted 4.11. When the two-position three-way directional valve 4.11 switches, the throttle bypass opens to the compensation container (1) (see the description of the operating status below).

[0018] The pump in the first pump assembly 2 can be configured as a gear pump or a plunger pump without flushing. A gear pump allows for easy adaptation to hydraulic cylinders configured as differential cylinders. In this case, the pump in the first pump assembly 2 is preferably configured as a dual-gear pump. A plunger pump is suitable for hydraulic cylinders configured as synchronized cylinders. The pump in the second pump assembly 3 can be configured as a plunger pump with or without flushing. If the pump is flushed, the bypass line with the throttle valve 4.12 and the two-position three-way directional valve 4.11 can be omitted. If the pump in the second pump assembly 3 is configured as a plunger pump without flushing or a simple gear pump, a bypass line with the throttle valve 4.12 and the two-position three-way directional valve 4.11 is required to avoid critical low speeds that could continuously damage the pump in the second pump assembly 3.

[0019] If the pump used has a specified pressure and suction port, it is preferable to always connect the pressure port to the hydraulic cylinder 6 and the suction port to the collection and compensation container 1.

[0020] Optionally, the device according to the invention may include two pressure relief valves connected to a control line. Figure 1a In this context, optional pressure relief valves are designated 4.5 and 4.6. Additionally, a flow sensor may optionally be arranged in the piping from the memory 5 to the associated control line. Figure 1a In this context, this optional flow sensor is designated 4.10. This flow sensor can be used to monitor the amount of hydraulic fluid withdrawn from the memory.

[0021] Optionally, the device according to the invention may include a so-called bypass unit, which represents an alternative memory filling possibility (see the description of operating states below). Figure 1aThis bypass unit is shown and indicated by 8. The bypass unit 8 is connected to the collection and compensation container 1 and the storage container 5, and includes a third pump assembly, indicated by 8.1. The third pump assembly 8.1 includes a driver and a pump connected to the driver. In a preferred embodiment, the third pump assembly 8.1 includes a constant-speed AC motor of a gear pump with a flange connection. However, the third pump assembly 8.1 can also be constructed differently. Optionally, the bypass unit may include a filter unit and / or a cooling unit. Figure 1a In the diagram, these units are represented by rectangles and labeled 8.2 and 8.3. The bypass unit 8 includes an electrically controlled directional valve (not shown). If the directional valve is closed, the reservoir 5 is charged via the pump of the bypass unit 8. If the directional valve is open, the bypass unit 8 filters and / or cools the hydraulic fluid in the collection and compensation container 1 in a pressureless cycle (if the bypass unit 8 includes a corresponding unit).

[0022] If the hydraulic cylinder 6 is configured as a differential cylinder, the memory 5 is preferably connected to the control line belonging to the rod side of the hydraulic cylinder 6. The inventors recognized that, in this case, the expected leakage at the rotary joint 7 is smaller. If a differential cylinder is used, it is advantageous that the flow ratio of the two pumps in the second pump unit 3 is adapted to the area ratio of the cylinders. Here, this adaptation does not need to be perfect, as any remaining difference is compensated for by the memory 5. However, this exchange volume only functions in the second operating mode.

[0023] Figure 1a The embodiments of the device according to the invention shown are applicable to any type of hydraulic cylinder, i.e., both differential cylinders and synchronizing cylinders. Figure 1b An implementation optimized specifically for and applicable to synchronizing cylinders is shown. Because... Figure 1a and 1b The implementation methods are largely the same, and only the following description is provided. Figure 1b Implementation methods and Figure 1a Differences in implementation methods.

[0024] exist Figure 1b In the illustrated embodiment, the first pump assembly 2 comprises only one pump with equal delivery rates in both rotational directions. This pump is preferably configured as a four-quadrant plunger pump. The pump's two ports are connected to control lines. Figure 1a The connection between the first pump device 2 shown and the collection and compensation container 1 is omitted.

[0025] exist Figure 1b In this implementation, the bypass unit 8 is no longer optional because the memory can no longer be charged by means of the pump device 2. This can only be done by the bypass unit, which has the advantage of being able to charge the memory without interrupting the control operation (see also below).

[0026] Optionally, the pump may include a flushing oil port connected to the bypass unit 8. A throttle valve is arranged in the corresponding connection line, which allows the flow rate of the flushing oil to be set. Furthermore, in this optional configuration, a pre-tightened check valve is arranged in the return line from the bypass unit 8 to the collection and compensation container 1. When the third pump unit 8.1 operates in a pressureless circulation (i.e., when the reversing valve is open), a portion of the circulation volume flows through the pump of the first pump unit 2 to cool it. This optional arrangement protects the pump of the first pump unit 2 from potential wear.

[0027] It should be mentioned that this device differs from the one in document DE 10 2017 106 693 B3. Figure 1a and 1b The embodiments of the device according to the invention shown do not include the emergency shut-off element disclosed therein. This is because in Kaplan-type hydraulic presses, emergency shut-off is not achieved (or only secondarily) by the position of the impeller blades, but (primarily) by closing the guide. An embodiment of the device according to the invention with emergency shut-off function will be further described below.

[0028] The following description Figure 1a and 1b The different operating states of the device shown.

[0029] The first operating state involves the control of hydraulic cylinder 6. As described above, this operating state is divided into a first operating mode (rapid change of impeller blade position) and a second operating mode (maintaining impeller blade position or moving them very slowly).

[0030] In the first operating mode, the second pump unit 3 is deactivated while the first pump unit 2 is activated. The two check valves 4.1 and 4.3 in the control line, as well as the check valve 4.7 to the memory, are opened, and the check valve 4.13 in the pressure line of the second pump unit 3 is closed (if it were open). Similar to the device described in document DE 10 2017 106 693 B3, the speed control actuator of the first pump unit 2 can bidirectionally regulate the hydraulic cylinder 6 in a four-quadrant operation within a highly efficient closed loop. Only the required energy needs to be applied to overcome the load and friction and move at a given speed.

[0031] exist Figure 1a In this implementation, any necessary exchange volume is either drawn from the collection and compensation container 1 or forced into the memory 5 via the check valve 4.7, which is unlocked in the first operating mode.

[0032] By establishing an open connection to the memory 5, pressure in the control lines on the memory side is ensured not to collapse during rapid movement in each embodiment. Thus, firstly, the driver of the first pump unit 2 operates under energy-optimal pressure conditions, and secondly, a critical pressure of less than 5 bar that could cause pump cavitation is avoided. The driver of the first pump unit 2 is designed to achieve maximum regulated speed. There is also no regulated energy from the memory 5. The maintained hydraulic fluid is used only for lubricating and cooling the rotary joint 7. Figure 1b In this embodiment, the internal losses of the first pump device are also compensated by the memory 5.

[0033] In the second operating mode, the position of the hydraulic cylinder 6 is maintained or regulated very slowly only by means of the second pump unit 3. The first pump unit 2 is inactive. The unlockable check valves 4.1 and 4.3 in the control lines are in the closed position. That is, the pilot valves 4.2 and 4.4 are in the spring-loaded, unenergized position. The reservoir 5 is connected to the interface of the rotary joint 7 via a (preferably adjustable) throttle valve 4.9 and an unlockable check valve 4.7 connected in parallel thereto, and mainly serves only as a reservoir for supplying hydraulic fluid, acting as lubricant and coolant for half of the rotary joint 7.

[0034] In the second operating mode, the unlockable check valve 4.7 to the memory 5 is in the closed position. Therefore, only the throttle valve 4.9 is active, reducing the cross-section and thus the pressure generated at the rotary joint 7. This also reduces leakage at the rotary joint 7 on the memory interface side. The pressure present on the memory side, combined with leakage on the non-memory side, causes a slow movement of the hydraulic cylinder 6 towards the non-memory side. To hold the hydraulic cylinder 6 in position, the second pump unit 3 must operate in the opposite direction to this movement. Therefore, the second pump unit 3 must compensate for leakage at the rotary joint 7 on the non-memory side. Since the second pump unit 3 is a speed-controlled driver, it must also apply energy only corresponding to the actual load and the actual required volumetric flow rate. The dimensions of the second pump unit 3 must be designed to compensate for leakage and to perform small regulating movements. To ensure a minimum speed of the second pump unit 2 depending on the applied pressure under all circumstances, a two-position three-way directional valve 4.11 with a pre-throttle valve 4.12 (if not a flushing plunger pump) is integrated into the pressure line of the second pump unit 3. Switching the solenoid valve opens a bypass to the collection and compensation container 1, which throttles the flow. The resulting leakage must also be compensated by the second pump unit 3, leading to an increase in delivery volume and thus an increase in rotational speed. This avoids the critical low speed at which the pump of the second pump unit 3 could potentially damage it. The critical low speed occurs when leakage at the rotary joint 7 decreases, which in turn can be caused by low ambient temperatures, as the viscosity of the hydraulic fluid decreases at low temperatures. This bypass operation of the second pump unit 3 can also be used to heat the hydraulic fluid.

[0035] The second pump device 3 also allows for smaller adjustable movements in two directions:

[0036] • If hydraulic cylinder 6 is to move toward the storage side, the associated pump must build up pressure and deliver it to the storage side.

[0037] • If hydraulic cylinder 6 is to move to the non-reservoir side, the associated pump must be depressurized and the hydraulic fluid discharged into the collection and compensation container 1. For this purpose, the unlockable check valve 4.13 in the pressure line is opened via the associated solenoid valve 4.14.

[0038] If the required hydraulic fluid delivery volume for the desired controlled movement exceeds the maximum delivery volume that the second pump unit 3 can provide, a switch from the second operating mode to the first operating mode occurs.

[0039] The reservoir pressure should be at least as high as the maximum pressure required for the moving hydraulic cylinder 6 to overcome hydraulic loads and friction. Otherwise, it may occur that during the required controlled movement, the reservoir is first charged to the maximum pressure before the cylinder movement can occur. In many cases, this will correspond to the conventional minimum system pressure p. R In the high-pressure region, p R The typical value is 80 or 110 bar. Since the reservoir only needs to hold the hydraulic fluid for lubrication and cooling, and a certain exchange volume, but not the hydraulic fluid for regulating the hydraulic cylinder, the reservoir volume depends only on the selected reservoir filling interval and the required exchange volume. A smaller reservoir filling interval results in a smaller reservoir volume, and vice versa. For the nominal reservoir pressure, p according to IEC 61362 can be used. 0max Maximum pressure: p 0max = 160 bar.

[0040] exist Figure 1a In this implementation, the memory loading function can be achieved through two alternative methods, or a combination of the two methods.

[0041] Similar to the device described in document DE 10 2017 106 693 B3, the memory 5 can be charged by the driver of the first pump device 2. For this purpose, the driver of the second pump device 3 is deactivated, and the two check valves 4.1 and 4.3 in the control line are locked. If the driver of the first pump device 2 now supplies fluid to the memory side, the memory 5 is charged. Due to leakage in the rotary joint and the inactive control of the drivers of the second pump device 3 and the first pump device 2, the hydraulic cylinder 6 drifts slowly in this situation. Because providing hydraulic fluid for lubrication and cooling must have higher priority than regulating quality in this case, this behavior is acceptable during the short period of memory charging.

[0042] Alternatively, a bypass unit 8 can be configured for memory charging. Its operation, with optional filtering and cooling functions, has been described above. If bypass unit 8 is configured for memory charging, the memory charging function can be redundantly executed. If memory charging cannot be performed using bypass unit 8, the driver of the first pump unit 2 can be used for memory charging.

[0043] According to Figure 1b In this implementation, only the bypass unit 8 can be used for memory loading.

[0044] In any case, the next switching point p of memory filling 0min The hydraulic fluid can be set very low because neither hydraulic fluid is needed for normal operation control nor for emergency shut-off functions.

[0045] The inventors designed a device according to the invention for a selected Kaplan-type hydraulic press. Oil is used as the hydraulic fluid. In the selected example, at p R =110 bar and p 0max A storage tank with a usable capacity of 40 liters of oil is generated between 160 bar and the specified value. The next switching point is p. 0min It is set to 120 bar. Therefore, p R and p 0min The volume between the two is 10 liters. For a typical high-pressure rotary joint with a leakage oil flow rate of 2 liters / minute, the reservoir must be refilled after 15 minutes. If refilling the reservoir fails, the remaining 10 liters of oil can provide an additional 5 minutes of lubrication and cooling to safely shut down the machine.

[0046] In a Kaplan-type hydraulic press, the position of the guide vanes is also adjusted in addition to the position of the impeller blades. In principle, the two control units can be independent of each other, with the control being managed by a common control device. However, the device of the present invention according to Figure 1 can be particularly advantageously combined with the device described in document DE 10 2017 106 693 B3. Such a combination... Figure 2 As shown in Figure 1. For clarity, the various components of the device according to Figure 1 are combined into a so-called impeller unit. The relevant components are outlined in Figure 1 with a dashed line, indicated by the number 4.

[0047] Figure 2 An apparatus for controlling a Kaplan-type hydraulic press according to the present invention is shown, wherein both the position of the impeller blades and the position of the guide vanes can be controlled by the apparatus. For controlling the position of the impeller blades, the apparatus includes an impeller unit, further indicated by 4. The impeller unit can be adjusted according to… Figure 1a or Figure 1b Construction. To adjust the position of the guide vanes, the device includes a so-called guide unit. Related components are... Figure 2 The area is enclosed in a dashed line, which is represented by the number 9. Figure 2 The guide unit 9 shown represents one particular implementation. However, the guide unit 9 can also be constructed differently. For various possible implementations of the guide unit 9, refer to DE 10 2017 106 693 B3, whose description, in order to explain the structure and function of the guide unit 9 in more detail, should be considered part of this document. Figure 2 For this reason, the markings of the components in guide unit 9 are adapted to those in document DE 10 2017 106 693 B3. Only to indicate that the relevant components belong to guide unit 9 are marked with "9." Therefore, it is only supplementary to mention here that impeller unit 4 and guide unit 9 use a common collection and compensation container 1, and the memory 9.5 of guide unit 9 is constructed as a plunger-type accumulator, and... Figure 2 The guide unit 9 shown does not have an optional quick-closing function. Furthermore, as... Figure 2 As shown, the device according to the invention may optionally include a bypass unit 8, which together provides the aforementioned memory charging function and, if necessary, filtration and cooling functions to the impeller unit 4 and the guide unit 9. If the impeller unit according to... Figure 1b In this configuration, bypass unit 8 is no longer optional. Furthermore, guide unit 9 can be similar to... Figure 1b The impeller unit is constructed such that pump unit 9.3 has only one pump, and the connecting pipeline from pump unit 9.3 to the collection and compensation container is omitted. In this case, hydraulic cylinder 9.6 must act as a synchronizing cylinder. Alternatively, in this case, the pump of pump unit 9.3 can also be supplied with flushing oil by bypass unit 8.

[0048] Finally, it should be mentioned that some Kaplan machines require the impeller blades to be adjusted to a predetermined position during emergency shut-off. This must continue to function even if the first pump unit 2 fails. To achieve this, the impeller unit 4 according to the invention can be readily equipped with the components required for the emergency shut-off function. These components are the same as those used for emergency shut-off in the guide unit 9. These components include at least components 9.71 (emergency shut-off valve), 9.72 (emergency shut-off solenoid valve), and at least one throttle valve. As in the guide unit 9, the energy required for emergency shut-off comes from the memory 5. Other optional components, such as those for rapid closure, or when more than one throttle valve is used to set the maximum closing speed, can be easily integrated into the impeller unit 4, similar to that described in document DE 10 2017 106 693 B3.

[0049] The inventors have redesigned six different Kaplan machines conventionally implemented in the past (see Part II of this document) according to the present invention, and compared the designs according to the invention with conventional designs in terms of required memory volume, memory cost, and container volume. If only impeller adjustment is considered, the following average reductions are achieved in the designs according to the invention:

[0050] - Memory volume: -77%

[0051] - Memory cost: -66%

[0052] - Container volume: -54%

[0053] Taking into account the combined impeller and guideway regulation, the following average reduction is obtained in the design according to the present invention:

[0054] - Memory volume: -69%

[0055] - Memory cost: -58%

[0056] - Container volume: -62%

[0057] List of reference numerals

[0058] 1 Collection and compensation container

[0059] 2 First pump unit

[0060] 3 Second pump unit

[0061] 4 Impeller Unit

[0062] 5. Memory

[0063] 6 hydraulic cylinders

[0064] 7 Rotary Joint

[0065] 8 Bypass Units

[0066] 9. Guide unit

[0067] 4.1 Check valve

[0068] 4.2 Pilot Valve

[0069] 4.3 Check Valve

[0070] 4.4 Pilot Valve

[0071] 4.5 Pressure relief valve

[0072] 4.6 Pressure relief valve

[0073] 4.7 Check Valve

[0074] 4.8 Pilot Valve

[0075] 4.9 Throttling valve

[0076] 4.10 Flow Sensor

[0077] 4.11 Two-position three-way directional valve

[0078] 4.12 Throttling valve

[0079] 4.13 Check valve

[0080] 4.14 Pilot Valve

[0081] 8.1 Third Pump Unit

[0082] 8.2 Filter Unit

[0083] 8.3 Cooling Unit

[0084] 9.3 Pump Unit of Guide Controller Unit

[0085] 9.5 Memory of the Guide Unit

[0086] 9.6 Hydraulic Cylinder of Guide Unit

[0087] 9.30 Pressure relief valve

[0088] 9.31 Pressure relief valve

[0089] 9.71 Emergency Shut-off Valve

[0090] 9.72 Emergency Shut-off Solenoid Valve

[0091] 9.81 Check Valve

[0092] 9.82 Check Valve

[0093] 9.91 Pilot Valve

[0094] 9.92 Pilot Valve

Claims

1. An apparatus for regulating a Kaplan-type hydraulic press having an impeller unit (4), said apparatus comprising a first pump unit (2) having a variable speed pump driver, a memory (5), a hydraulic cylinder (6), two unlockable check valves (4.1, 4.3) and two pilot valves (4.2, 4.4) for unlocking the check valves (4.1, 4.3), wherein, The first pump assembly (2) includes at least one pump having a reversible delivery direction, the pump being connected to a variable speed pump driver such that the pump can be driven by the pump driver in both delivery directions, and wherein the device further includes a collection and compensation container (1), characterized in that the impeller unit (4) includes a second pump assembly (3) having a variable speed pump driver, a rotary joint (7), a throttle valve (4.9), two additional unlockable check valves (4.7, 4.13) and two additional pilot valves (4.8, 4.14) for unlocking the additional check valves (4.7, 4.13), and wherein the second pump assembly (3) includes an additional pump having a reversible delivery direction, the additional pump being connected to a pump driver. The pump is connected to a variable-speed pump driver, allowing the additional pump to be driven in both delivery directions. The first port of the first pump assembly (2) is connected to the first side of the hydraulic cylinder (6) via a first control line and a rotary joint (7), and the second port of the first pump assembly (2) is connected to the second side of the hydraulic cylinder (6) via a second control line and a rotary joint. Each section of the control line extending from the first pump assembly (2) to the rotary joint (7) is equipped with an unlockable check valve (4.1, 4.3), oriented such that hydraulic fluid flows towards the rotary joint (7) in any state of the check valves (4.1, 4.3). The second pump assembly (3) is connected to the collection and compensation container (1) on one side, and to the first control line via a pressure line extending between the relevant check valve (4.1) and the rotary joint (7), wherein a check valve (4.13) is arranged in the pressure line, the check valve being oriented such that hydraulic fluid can pass toward the first control line in any state of the check valve (4.13), and wherein the reservoir (5) is connected to the second control line via a throttle valve (4.9), the section extending between the relevant check valve (4.3) and the rotary joint (7). The impeller unit (4) further includes a pipeline connecting the memory (5) to the check valves (4.1, 4.3, 4.7, 4.13) respectively, so that hydraulic fluid can flow through the check valve (4.7) from the second control line to the memory (5) in any state of the check valve (4.7), and wherein the impeller unit (4) also includes a pipeline connecting the memory (5) to these check valves (4.1, 4.3, 4.7, 4.13) respectively, so that these check valves (4.1, 4.3, 4.7, 4.13) can be unlocked, and wherein the pilot valves (4.2, 4.4, 4.8, 4.14) are respectively arranged in the pipeline between the memory (5) and these check valves (4.1, 4.3, 4.7, 4.13), such that the pilot valve (4.9)...Each of the following (2, 4.4, 4.8, 4.14) can unlock a check valve (4.1, 4.3, 4.7, 4.13).

2. The apparatus according to claim 1, wherein, The device includes a bypass unit (8), wherein the bypass unit (8) is connected to the collection and compensation container (1) and the memory (5), wherein the bypass unit (8) includes a third pump device (8.1), wherein the third pump device (8.1) includes a driver and a pump connected to the driver.

3. The device according to claim 1 or 2, wherein, The hydraulic cylinder (6) is constructed as a synchronous cylinder.

4. The device according to claim 1 or 2, wherein, The hydraulic cylinder (6) is constructed as a differential cylinder.

5. The device according to any one of the preceding claims, wherein, The first pump device (2) includes a first pump and a second pump, which have reversible delivery directions and are connected to a pump driver with variable speed, such that the pumps can be driven by the pump driver in both delivery directions. The interface of the first pump is connected to a first side of the hydraulic cylinder (6) via a first control line and a rotary joint (7), and the interface of the second pump is connected to a second side of the hydraulic cylinder (6) via a second control line and a rotary joint. The remaining interfaces of the first pump and the second pump are connected to the collection and compensation container (1), such that in one driving direction of the first pump device (2), the first pump can deliver hydraulic fluid from the collection and compensation container (1) to the hydraulic cylinder (6), and the second pump can deliver hydraulic fluid from the hydraulic cylinder (6) to the collection and compensation container (1).

6. The device according to claims 2 and 3, wherein, The first pump device (2) includes exactly one pump with equal delivery in both rotational directions, and wherein the interface of the pump is connected to a control line.

7. The device according to claim 6, wherein, The pump structure of the first pump device (2) is a four-quadrant plunger pump.

8. The device according to claim 7, wherein, The pump of the first pump device (2) includes a flushing oil port connected to the bypass unit (8), wherein a throttle valve is arranged in the corresponding connecting line, and wherein a pre-tightened check valve is arranged in the return line from the bypass unit (8) to the collection and compensation container (1).

9. The device according to any one of the preceding claims, wherein, The impeller unit (4) includes an additional throttle valve (4.12) and a two-position three-way directional valve (4.11), wherein the throttle valve (4.12) and the two-position three-way directional valve (4.11) are arranged in a pipeline extending from the pressure line to the collection and compensation container (1).

10. The device according to any one of the preceding claims and in conjunction with claim 4, wherein, The second control line is connected to the rod side of the hydraulic cylinder (6).

11. The device according to claim 4 or 10 in conjunction with claim 5, wherein, The first pump and the second pump of the first pump device (2) are configured as gear pumps.

12. The device according to any one of the preceding claims and in conjunction with claim 9, wherein, The pump configuration of the second pump device (3) is a gear pump or a non-flushing plunger pump.

13. The device according to any one of the preceding claims, wherein, The impeller unit (4) includes a flow sensor (4.10) arranged in a conduit extending between the memory (5) and the second control line.

14. The device according to any one of the preceding claims, wherein, The impeller unit (4) includes two pressure relief valves (4.5, 4.6), one of which is connected to the first control line and the other is connected to the second control line.

15. The device according to any one of the preceding claims, wherein, The impeller unit (4) includes an additional throttle valve, an emergency shut-off valve (9.71), and an emergency shut-off solenoid valve (9.72).

16. The device according to any one of the preceding claims, wherein, The device includes a guide unit (9) connected to the collection and compensation container (1).

17. The device according to claims 2 and 16, wherein, The guide unit (9) includes a memory (9.5), and the bypass unit (8) is connected to the memory (9.5) of the guide unit (9).

18. The device according to any one of claims 2 to 17, wherein, The bypass unit (8) includes a filter unit (8.2).

19. The device according to any one of claims 2 to 18, wherein, The bypass unit (8) includes a cooling unit (8.3).

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