Method for forming a quadrant control valve system, quadrant control valve system and hydraulic system

Abstract

A method for forming a quadrant control valve system V2 for a hydraulic system 200 is provided. The quadrant control valve system V2 comprises at least one control valve arrangement SVA2, which includes at least one control valve SV1, SV2, SV3, SV4, an electronic valve controller C2, and a control valve sensor system. The method essentially comprises steps of automated quadrant-based load case analysis, automated circuit diagram synthesis, and automated controller synthesis, as well as the implementation of the synthesized circuit diagram and the implementation of the synthesized controller.

Description

[0001] The present invention relates to a method of forming a quadrant control valve system, a quadrant control valve system and a hydraulic system.

[0002] A wide variety of control valve systems for controlling hydraulic consumers, such as hydraulic cylinders or hydraulic motors, in hydraulic systems are known from the prior art. Modern control valve systems comprise a control valve arrangement for each hydraulic consumer to be controlled, a control valve sensor system, and an electronic valve control system. Each control valve arrangement comprises at least one electromagnetically or electro-hydraulically actuated control valve. The electronic valve control system typically comprises a controller for the control valve arrangement(s), with the controller being implemented as software in the electronic valve control system. A common controller for all control valve arrangements or a separate controller for each control valve arrangement can be provided. The sensor data from the control valve sensor system is used to control the variables to be controlled.The control valve sensor system can consist of sensors distributed across the hydraulic system and the control valve system (e.g. pressure, volume flow, temperature or similar sensors), which are provided as separate components.

[0003] Such control valve systems are specifically designed for the respective application, i.e., the hydraulic system to be controlled or the hydraulic consumer(s) to be controlled. The implementation of such control valve systems requires a high level of individual development effort, which continues to rise with the increasing complexity of the hydraulic systems to be controlled and the increasing demands on precision and stability at the operating points to be controlled.

[0004] In addition, with regard to increasingly required functionalities such as anomaly detection, condition monitoring or predictive maintenance, it is also necessary to provide control valve systems that can implement these functionalities adaptively.

[0005] From DE 101 38 389 A1, for example, an electro-hydraulic device for controlling a double-acting motor in a tractor hitch control device is known, with which a four-quadrant operation with lifting, lowering, pressing and yielding can be controlled via four edges of a control valve.

[0006] From DE 10 2021 204 544 A1, for example, a method and a control unit for operating a hydraulic cylinder are known, wherein the method proposes a physical white box model for the plausibility check of output data of a data-based black box model, whereby a grey box model is used in combination.

[0007] For example, EP 2 203 791 B1 discloses a controller structure for a hydraulic cylinder unit with an underlying state controller.

[0008] From EP 2 1488 958 B1, for example, a method for recovering potential energy during a load lowering process is known, which is implemented on the basis of four load quadrants.

[0009] Against this background, it is an object of the present invention to demonstrate a holistic approach for the most automated implementation of an adaptive, self-learning control valve system.

[0010] The object is achieved firstly with a method according to the invention for forming a quadrant control valve system for a hydraulic system according to claim 1. Advantageous further developments are described in the dependent claims.

[0011] Furthermore, the problem is solved with a quadrant control valve system according to claim 12 and a hydraulic system according to claim 14.

[0012] According to the invention, a method for forming a quadrant control valve system for a hydraulic system is provided. The hydraulic system comprises at least one hydraulic consumer that is controlled via the quadrant control valve system. The quadrant control valve system comprises a control valve arrangement for each hydraulic consumer of the hydraulic system to be controlled, a control valve sensor system, and an electronic valve controller, each control valve arrangement comprising at least one control valve. The method comprises the following steps: - Performing an automated quadrant-based load case analysis of the entire hydraulic system to be controlled based on hydraulic system requirement data; - performing a circuit diagram synthesis for the quadrant control valve system based on the quadrant-based load case analysis, wherein the circuit diagram synthesis comprises a role assignment for each control valve of each control valve arrangement based on the quadrant-based load case analysis; - Performing a controller synthesis for the quadrant control valve system based on the synthesized circuit diagram and role assignment; - Implementing the synthesized circuit diagram of the quadrant control valve system; and - Implementing the synthesized controller in the electronic valve control of the quadrant control valve system.

[0013] Preferably, the circuit diagram synthesis, the role assignment and / or the controller synthesis are also carried out automatically.

[0014] The control valve sensor system generally includes sensors for all variables required for controlling the variables to be controlled (e.g., pressure, volume flow, and / or temperature sensors). Preferably, each control valve includes at least one integrated fluid sensor that is part of the control valve sensor system. A fluid sensor is any type of sensor that measures a hydraulic fluid parameter relevant to controlling the variables to be controlled.

[0015] In this case, the design of a control valve system includes both the hardware implementation of hydraulic circuit diagrams and the software implementation of the necessary control and regulation programs in the electronic valve control system.

[0016] A quadrant control valve system is a control valve system that is based on a quadrant-based load case analysis.

[0017] A quadrant-based load case analysis is the assignment of all load cases occurring in the hydraulic system to a four-quadrant field for each hydraulic consumer. A four-quadrant field defines the possible movement and load directions of an individual hydraulic consumer. Depending on the load cases actually occurring at the respective hydraulic consumer, a varying number of quadrants of the respective four-quadrant field actually contain operating points that correspond to the load cases occurring for this specific hydraulic consumer. From such a quadrant-based load case analysis, conclusions can be drawn about the quadrant control valve system required for the hydraulic system to be controlled. The quadrant-based load case analysis can be automated, for example, using a lookup table, a library, or using machine learning methods.

[0018] In this context, a quadrant control valve system is also understood to mean a control valve system that, depending on the requirements of the hydraulic consumer to be controlled, comprises one, two, or four control valves in a control valve arrangement for a hydraulic consumer. Such a quadrant control valve system offers a particularly high degree of freedom, both in terms of its technical design, depending on how many control valves are actually required, and in terms of the individual control and regulation of the individual control valves when fully equipped with four control valves. This allows for the realization of particularly efficient control valve systems and, on the other hand, the implementation of even complex control and regulation requirements with particular flexibility.

[0019] In this case, circuit diagram synthesis refers to the, preferably automated, creation of a hydraulic circuit diagram for the quadrant control valve system. A, preferably automated, role assignment for each control valve also refers to the fact that, based on the automated quadrant-based load case analysis, each control valve is assigned a specific role (e.g., fully open, fully closed, regulating) for each occurring load case, preferably automatically. Both the automated circuit diagram synthesis and the automated role assignment are carried out, for example, based on a lookup table or a library in which corresponding combinations of load cases, circuit diagrams, and roles are stored, or using machine learning methods.

[0020] Controller synthesis involves designing a controller for each control valve in a quadrant control valve system. Automated controller synthesis is possible using machine learning methods. Based on, for example, the requirements data, the quadrant-based load case analysis, the synthesized circuit diagram, and / or the role assignment for each control valve, the behavior of the entire hydraulic system is identified using a computer-based model structure, and system equations for the entire hydraulic system are extracted. A corresponding controller can then be automatically synthesized from the extracted system equations.As a computer-based model structure, for example, an ANARX structure (additive nonlinear autoregressive exogenous model), an LSTM structure (long short-term memory), an ARMA structure (autoregressive-moving-average) and / or an RNN structure (recurrent neural network) can be used.

[0021] Implementing the synthesized circuit diagram refers to the hardware implementation of the quadrant control valve system.

[0022] The implementation of the synthesized controller refers to the software-based embedding of the synthesized controller in the electronic valve control system. The electronic valve control system can comprise either a central electronic valve control system for all control valve assemblies of the quadrant control valve system or a multitude of electronic valve controls for individual control valve assemblies or even individual control valves.

[0023] It should also be noted that, according to the invention, a control valve arrangement can also control two or more hydraulic consumers simultaneously (for example, in a lifting device with four lifting cylinders controlled via a common control valve arrangement). However, each hydraulic consumer to be controlled is assigned a control valve arrangement for controlling the respective hydraulic consumer.

[0024] The method according to the invention demonstrates a holistic approach to the most automated implementation of a quadrant control valve system.

[0025] Preferably, the result of the automated quadrant-based load case analysis maps all load cases occurring in the hydraulic system and all transitions between the load cases in a four-quadrant field for each hydraulic consumer, with the four quadrants each mapping a unique combination of positive or negative load and positive or negative movement of the corresponding hydraulic consumer in a two-axis coordinate system. Positive and negative loads include, for example, pushing and pulling loads. Positive and negative movements include, for example, the extension and retraction of a hydraulic cylinder or the rotation of a hydraulic motor in a first and a second direction. In this way, all load cases occurring and all transitions between load cases for each hydraulic consumer can be mapped in a four-quadrant field.On this basis, it is easy to automatically select how many control valves are required per hydraulic consumer and which roles the respective control valves must fulfill for each load case.

[0026] If the hydraulic system comprises at least two hydraulic consumers that are operated exclusively sequentially, it is expedient to perform an automated load case analysis separately for each hydraulic consumer. Alternatively, if the hydraulic system comprises at least two hydraulic consumers that are also operated in parallel, it is expedient to perform an automated load case analysis separately for each hydraulic consumer and, in addition, an automated load case analysis for each case in which at least two hydraulic consumers are operated in parallel. If hydraulic consumers are operated in parallel, the use of special circuit diagram architecture provides the possibility of energy recovery.In other words, for example, energy from a hydraulic consumer that is usually converted into heat (i.e., lost) as part of a throttle control can be used to operate another hydraulic consumer.

[0027] Advantageously, the circuit diagram synthesis is performed automatically and includes an automated selection of a number of required control valves for each control valve arrangement.

[0028] By default, a single control valve arrangement in the quadrant control valve system comprises four control valves. However, since there are also simple applications where not all four control valves are required, it is advantageous to select the actually required number of control valves for each control valve arrangement during automated schematic synthesis. This reduces both manufacturing costs and system complexity.

[0029] Furthermore, it is advantageous if each control valve is an electromagnetically (or electrohydraulically) actuated 2 / 2-way control valve, preferably designed as a valve cartridge. Each control valve arrangement preferably comprises at least two control valves and particularly preferably four control valves. In particular, each control valve is a proportional, electromagnetically actuated 2 / 2-way control valve. The use of exclusively electromagnetically actuated 2 / 2-way control valves simplifies the system architecture and allows the flexible use of standardized components. By using four electromagnetically actuated 2 / 2-way control valves in a single control valve arrangement, the control valve arrangement in question can control any conceivable hydraulic consumer and precisely and reliably adjust the desired operating points with a high degree of flexibility.

[0030] The hydraulic system's requirement data expediently includes measurement and / or simulation data of the hydraulic system. Optionally, specific customer requirements, such as specific specifications regarding energy efficiency or maximum energy consumption of the hydraulic system to be controlled at certain operating points, can also be part of the requirement data. This allows even complex customer specifications to be automatically implemented in a fully developed quadrant control valve system.

[0031] It is advantageous if the method further comprises the following downstream steps: - Reading of sensor data recorded and stored during operation of the quadrant control valve system and - Optimize the role assignment of the individual control valves and the synthesized controller based on the recorded and stored sensor data.

[0032] By reading sensor data recorded and stored during operation of the quadrant control valve system, optimization is based on real measurement data from the developed quadrant control valve system, thus providing the most accurate and realistic data possible. Accordingly, a more comprehensive database is available in the optimization step, especially for controller synthesis, leading to even better controller synthesis results. Additionally or alternatively, the optimization step can also be based on modified or new requirement data from the hydraulic system. This allows for subsequent adaptation of the developed quadrant control valve system to changing environmental conditions, wear patterns, or even changed customer requirements as part of an update.

[0033] Furthermore, it is expedient if the downstream steps of reading and optimization are also performed automatically during operation of the quadrant control valve system. Preferably, the downstream steps are performed automatically by the valve controller of the quadrant control valve system. This can occur either continuously or at predetermined intervals. This creates a fully self-learning, adaptive quadrant control valve system that independently adapts itself (and in particular the implemented synthesized controllers) to changing ambient conditions and / or signs of wear.

[0034] It is also advantageous if the automated steps of the process are carried out computer-based using machine learning methods. Machine learning methods preferably include convolutional neural networks (CNNs), transformer models, recurrent neural networks (RNNs), and / or knowledge-based methods. Knowledge-based methods can also be referred to as "rule-based systems" or "expert systems." These form a subfield of artificial intelligence / machine learning. With knowledge-based methods, recommendations for action and / or conclusions are derived from an existing knowledge base, usually created and maintained by experts. Fixed rule-based systems that influence decision-making based on "if-then queries," for example, are a simple example. Another example is decision trees.In contrast to neural networks, decision-making with knowledge-based methods is relatively transparent and comprehensible. In this case, knowledge-based methods could be used, for example, in automated circuit diagram synthesis. For example, many different versions of (sub-)circuit diagrams and the corresponding roles of the respective control valves would be stored in a library / lookup table. Based on fixed rules and in combination with given requirement data, automated circuit diagram synthesis could be performed on this basis.

[0035] According to the invention, a quadrant control valve system for a hydraulic system is further provided. The hydraulic system comprises at least one hydraulic consumer controlled via the quadrant control valve system. The quadrant control valve system comprises a control valve arrangement for each hydraulic consumer of the hydraulic system to be controlled, a control valve sensor system, and an electronic valve controller. The quadrant control valve system was designed according to a method described above. The control valve sensor system is preferably integrated into the individual control valves.

[0036] The quadrant control valve system according to the invention provides an automatically implemented, adaptive control valve system.

[0037] It is advantageous if the quadrant control valve system further includes a memory unit in which the sensor data recorded by the control valve sensors during operation of the quadrant control valve system is stored. This allows the downstream optimization steps to be implemented easily and automatically during operation or as part of an update procedure on the quadrant control valve system.

[0038] The invention is explained in more detail below with reference to exemplary embodiments shown in the figures. These schematically show: Fig. 1 shows a circuit diagram of a hydraulic system according to a first embodiment; Fig. 2 exemplary load cases for the first embodiment according to Fig. 1; Fig. 3 a four-quadrant field for the Fig. 2 load cases shown; Fig. 4 shows a circuit diagram of a hydraulic system according to a second embodiment; Fig. 5 exemplary load cases for the second embodiment according to Fig. 4; Fig. 6 a four-quadrant field for the Fig. 5 load cases shown; Fig. 7 shows a circuit diagram of a hydraulic system according to a third embodiment; Fig. 8 shows a circuit diagram of a hydraulic system according to a fourth embodiment; and Fig. 9 a simplified block diagram of a method according to the invention.

[0039] In Fig. 1 shows the schematic circuit diagram of a hydraulic system 100 according to a first embodiment. The hydraulic system 100 comprises a hydraulic pump 10, a hydraulic consumer 12, which in this embodiment is designed as a hydraulic motor, a quadrant control valve system V1 with a control valve arrangement SVA1, which includes a control valve SV, and a tank 14. As shown in Fig. 1, the control valve SV in this case is a proportional electromagnetically actuated 2 / 2-way control valve with an electromagnetic actuator 16 and a return spring 18, which preloads the control valve SV into its closed initial position. Furthermore, two pressure sensors PS are integrated into the control valve SV, of which Fig. 1, only one is shown schematically. The pressure sensors PS are part of a control valve sensor system of the quadrant control valve system V1 and measure the pressures upstream and downstream of the control edge of the control valve SV. In addition, the quadrant control valve system V1 includes an electronic valve controller C1 and a memory unit M1.

[0040] The hydraulic system 100 of the first embodiment describes the configuration of a hydraulic cable winch, wherein the hydraulic motor 12 actuates the cable winch and the quadrant control valve system V1 controls the volume flow flowing from the hydraulic pump 10 via the hydraulic motor 12.

[0041] In Fig. 2, the load cases occurring in the hydraulic system 100 and their transitions into three phases PH1, PH2 and PH3 are shown as examples. The pressures upstream and downstream of the hydraulic motor 12 (p A and p B) is plotted over time t. For each of the three phases PH1, PH2, and PH3, both a direction of movement s of the hydraulic motor 12 and a force F acting opposite to the direction of movement s are shown.

[0042] In the present case, the hydraulic system 100 is designed exclusively for the hydraulic motor 12 (the cable winch) to pull a load (represented by the force F) in the direction of movement s.

[0043] The three phases PH1, PH2 and PH3 in Fig. 2 correspond to three load cases. In the first load case LF1 and the third load case LF3 in phases PH1 and PH2, the hydraulic motor 12 is rotated in the direction of movement s without any load acting. The load cases LF1 and LF3 are therefore identical in this case. In the second load case LF2 in phase PH2, the hydraulic motor 12 rotates in the direction of movement s and pulls a load, which is represented by the force F. In the p / t diagram in Fig. 2 clearly shows how the pressures pA and pB in front of and behind the hydraulic motor 12 differ during the individual phases PH1 to PH3 and also how the transitions of the pressure curves between the individual phases PH1 to PH3 are represented.

[0044] In Fig. 3 are the Fig. The load cases LF1 to LF3 illustrated in Figure 2 are depicted in a four-quadrant field. The four-quadrant field consists of a first quadrant QI, a second quadrant QII, a third quadrant QIII, and a fourth quadrant QIV. The direction of motion s of the hydraulic motor 12 is plotted on the abscissa of the four-quadrant field. A load p acting on the hydraulic motor 12 is plotted on the ordinate.

[0045] As in Fig. As can be seen in Figure 3, the first load case LF1 and the third load case LF3 correspond to a point on the abscissa between the second quadrant QII and the third quadrant QIII. Therefore, no load p is applied here, but the hydraulic motor 12 rotates such that the cable winch is retracted (negative direction of movement s). The second load case LF2, on the other hand, corresponds to a point in the third quadrant QIII. Here, the hydraulic motor 12 rotates such that the cable winch is retracted, and at the same time, the force F pulls on the cable winch (negative load p).

[0046] As in Fig. 3, in the four-quadrant field representing the three load cases LF1 to LF3 of the hydraulic system 100 of the first embodiment (cable winch), there are no transitions between the individual quadrants QI to QIV during the transition between the individual load cases LF1 to LF3. From the Fig. The four-quadrant field for the hydraulic system 100 shown in Figure 3 can therefore in principle be directly applied to the Fig. 1 shown form of the quadrant control valve system V1 with only one control valve SV (simplest form of a quadrant control valve system).

[0047] In Fig. 4 shows the schematic circuit diagram of a hydraulic system 200 according to a second embodiment. The hydraulic system 200 comprises a hydraulic pump (not shown), a hydraulic cylinder 20 (hydraulic consumer), a quadrant control valve system V2 with a control valve arrangement SVA2, and a tank (not shown). The control valve arrangement SVA2 has a first control valve SV1, a second control valve SV2, a third control valve SV3, and a fourth control valve SV4. As shown in Fig. As can be seen in Figure 4, the control valves SV1 to SV4 are identical to the control valve SV of the first embodiment, which is why further details will not be discussed here. The quadrant control valve system V2 also includes an electronic valve control C2 and a memory unit M2.

[0048] In the hydraulic system 200 according to the second embodiment, the first control valve SV1 controls the supply of hydraulic fluid from the pump (see p P in Fig. 4) to a rod side 22 of the hydraulic cylinder 20. The second control valve SV2 controls the outflow of hydraulic fluid from the rod side 22 of the hydraulic cylinder 20 towards the tank (see p T in Fig. 4). The third control valve SV3 controls the supply of hydraulic fluid from the pump to a piston side 24 of the hydraulic cylinder 20. The fourth control valve SV4 controls the outflow of hydraulic fluid from the piston side 24 of the hydraulic cylinder 20 towards the tank.

[0049] The hydraulic system 200 schematically corresponds to the lifting device of a forklift truck. The corresponding load cases LF1 to LF5 are shown in Fig. 5. Also in Fig. 5 are the pressure curves p A (here: pressure on piston side 24) and p B (here: pressure on the rod side 22) over the individual load cases in five phases PH1 to PH5. The first load case LF1 and the third load case LF3 correspond to an extension of the hydraulic cylinder 20 without load. The second load case LF2 corresponds to an extension of the hydraulic cylinder 20 with load (see force F opposite to the direction of movement s in Fig. 5). The fourth load case LF4 corresponds to a retraction of the hydraulic cylinder 20 without load. The fifth load case LF5 corresponds to a retraction of the hydraulic cylinder 20 under load (see force F in the direction of movement s in Fig. 5).

[0050] In Fig. 6 are again the Fig. 5, the load cases LF1 to LF5 of the hydraulic system 200 are shown in a four-quadrant field. The first and third load cases LF1 and LF3 correspond to the same point on the abscissa between the first quadrant QI and the fourth quadrant QIV of the four-quadrant field (positive direction of movement s, extension of the hydraulic cylinder 20, no load p). The second load case LF2 corresponds to a point in the fourth quadrant QIV (positive direction of movement s, negative load p). The fourth load case LF4 corresponds to a point on the abscissa between the second quadrant QII and the third quadrant QIII (negative direction of movement s, retraction of the hydraulic cylinder 20, no load). The fifth load case LF5 corresponds to a point in the third quadrant QIII of the four-quadrant field (negative direction of movement, negative load p).

[0051] As in Fig. 6, load transitions between the third quadrant QIII and the fourth quadrant QIV are possible in the hydraulic system 200. For example, it is possible to transition directly from the second load case LF2 (extension of the hydraulic cylinder 20 under a pressing load p) to the fifth load case LF5 (retraction of the hydraulic cylinder 20 under a pressing load p) and vice versa. Fig. The four-quadrant field for the hydraulic system 200 shown in Figure 6 can therefore in principle be directly applied to the Fig. 4 shown form of the quadrant control valve system V2 with four control valves SV1 to SV4 (standard form of a quadrant control valve system).

[0052] In Fig. Figure 7 shows an exemplary circuit diagram of a hydraulic system 300 according to a third embodiment with a quadrant control valve system V3 with a control valve arrangement SVA3, which includes a first control valve SV1 and a second control valve SV2, a hydraulic pump 10, a single-acting hydraulic cylinder 26 with automatic return via a return spring 28, and a tank 14. The hydraulic system 300 corresponds, for example, to the control of an adjusting cylinder of an axial piston variable displacement pump. As shown in Fig. 7, the control valve arrangement SVA3 of the quadrant control valve system V3 requires only two control valves SV1 and SV2 to control the piston-side inlet and outlet of the single-acting hydraulic cylinder 26. The quadrant control valve system V3 further comprises an electronic valve control C3 and a storage unit M3, which in Fig. 7 are shown schematically.

[0053] In Fig. Figure 8 shows an exemplary circuit diagram of a hydraulic system 400 according to a fourth exemplary embodiment with a quadrant control valve system V4, a hydraulic pump 10, a tank 14, and a plurality of hydraulic cylinders 30, 32, 34, 36 as hydraulic consumers. Specifically, the hydraulic system 400 corresponds to the configuration of a telescopic forklift with a tilt cylinder 30, a lifting cylinder 32, a telescopic cylinder 34, and a compensating cylinder 36. The tilt cylinder 30, the lifting cylinder 32, and the telescopic cylinder 34 represent hydraulic consumers to be controlled in the hydraulic system 400, which are each controlled via a control valve arrangement SVA4, a control valve arrangement SVA5, and a control valve arrangement SVA6 of the quadrant control valve system V4. The control valve arrangements SVA4, SVA5, and SVA6 each comprise four control valves, which are shown in Fig. 8 are not further specified. The quadrant control valve system V4 further comprises an electronic valve control C4 and a memory unit M4, which are Fig. 8 are shown schematically. For the sake of clarity, no connections between the electronic valve control C4 and the other components of the quadrant control valve system V4 are shown. The same applies to the storage unit M4.

[0054] With reference to Fig. 9, a method according to the invention for forming a quadrant control valve system for a hydraulic system is now described. The described method is applicable to all quadrant control valve systems V1 to V4 described above as examples for the hydraulic systems 100 to 400. The hydraulic systems 100 to 400 essentially serve to illustrate different degrees of complexity of quadrant control valve systems. For the sake of simplicity, the description of the method according to the invention will hereinafter refer to the quadrant control valve system V2 according to the Fig. 4 to Fig. 6 shown embodiment of the hydraulic system 200.

[0055] The method according to the invention essentially comprises steps S1 to S5 and optionally further steps S6 and S7. Steps S1 to S3 are carried out computer-based using machine learning methods.

[0056] In step S1, an automated load case analysis of the entire hydraulic system 200 to be controlled is carried out based on requirement data of the hydraulic system 200. The requirement data in this case comprise measurement and / or simulation data of the hydraulic cylinder 20, as exemplified in Fig. 5. The result of the automated quadrant-based load case analysis of step S1 corresponds to the Fig. 6 shows an example of a four-quadrant field for the load cases of the hydraulic system 200.

[0057] In step S2, an automated circuit diagram synthesis is performed for the quadrant control valve system V2 based on the quadrant-based load case analysis. The circuit diagram synthesis includes an automated role assignment for each control valve SV1, SV2, SV3, and SV4 of the control valve arrangement SVA2 based on the quadrant-based load case analysis. Specifically, the role assignment for the Fig. 5 schematically illustrated load cases LF1 to LF5 with reference to the control valves SV1 to SV4, the following result: When the hydraulic cylinder 20 extends (load cases LF1 to LF3), the third control valve SV3 controls the supply of hydraulic fluid to the piston side 24 of the hydraulic cylinder 20 from the pump. The second control valve SV2 is fully open in load cases LF1 to LF3 in order to relieve the rod side 22 towards the tank. The first control valve SV1 and the fourth control valve SV4, on the other hand, are fully closed when extending (load cases LF1 to LF3). When the cylinder retracts (load cases LF4 and LF5), there is a risk that the pressing load according to load case LF4 will additionally accelerate the hydraulic cylinder 20 in its downward movement. To prevent this, the retraction of the hydraulic cylinder 20 according to load cases LF4 and LF5 is controlled via the fourth control valve SV4.When the hydraulic cylinder 20 retracts, the first control valve SV1, which controls the supply from the pump to the rod side 22 of the hydraulic cylinder, is fully open. The speed of the hydraulic cylinder 20 is controlled solely by the opening degree of the fourth control valve SV4. The second control valve SV2 and the third control valve SV3 are fully closed when the hydraulic cylinder 20 retracts.

[0058] In step S3, an automated controller synthesis for the quadrant control valve system V2 is performed based on the synthesized circuit diagram and the role assignment from step S2.

[0059] In step S4, the synthesized circuit diagram of the quadrant control valve system V2 is Fig. 4 implemented in hardware.

[0060] In step S5, the controller synthesized in step S3 is implemented in the electronic valve control C2 of the quadrant control valve system V2.

[0061] During operation of the quadrant control valve system V2 in the hydraulic system 200, the storage unit M2 stores all sensor data acquired by the control valve sensors of the quadrant control valve system V2. In particular, this includes the sensor data from the pressure sensors PS integrated in the control valves SV1 to SV4.

[0062] In step S6, the sensor data recorded during the operation of the quadrant control valve system V2 and stored in the storage unit M2 are read out.

[0063] In step S7, the role assignment of the individual control valves SV1 to SV4 as well as the synthesized controller in the electronic valve control C2 are optimized based on the recorded and stored sensor data. REFERENCE SYMBOL 10 Hydraulic pump 12 Hydraulic motor (hydraulic consumer) 14 tanks 16 electromagnetic actuator 18 Return spring 20 hydraulic cylinders (hydraulic consumers) 22 rod side 24 Piston side 26 single-acting hydraulic cylinders 28 Return spring 30 tilt cylinders 32 lifting cylinders 34 telescopic cylinders 36 compensating cylinders 100 to 400 hydraulic system C1 to C4 electronic valve control F Force LF1 to LF5 load cases M1 to M4 storage unit p load PH1 to PH5 phases PS pressure sensor s direction of movement S1 to S7 process steps SV control valve SV1 first control valve SV2 second control valve SV3 third control valve SV4 fourth control valve SVA1 to SVA6 control valve arrangement V1 to V4 quadrant control valve system

Claims

[1] Method for forming a quadrant control valve system (V1, V2, V3, V4) for a hydraulic system (100, 200, 300, 400), wherein the hydraulic system (100, 200, 300, 400) comprises at least one hydraulic consumer (12, 20, 30, 32, 34) which is controlled via the quadrant control valve system (V1, V2, V3, V4), wherein the quadrant control valve system (V1, V2, V3, V4) comprises a control valve arrangement (SVA1 to SVA6) for each hydraulic consumer (12, 20, 30, 32, 34) of the hydraulic system (100, 200, 300, 400) to be controlled, a control valve sensor system and an electronic valve control (C1, C2, C3, C4), wherein each control valve arrangement (SVA1 to SVA6) comprises at least one control valve (SV, SV1, SV2, SV3, SV4), and the method comprising the following steps: - Performing an automated quadrant-based load case analysis of the entire hydraulic system to be controlled (100, 200, 300, 400) based on requirement data of the hydraulic system (100, 200, 300, 400); - performing a circuit diagram synthesis for the quadrant control valve system (V1, V2, V3, V4) based on the quadrant-based load case analysis, wherein the circuit diagram synthesis comprises a role assignment for each control valve (SV, SV1, SV2, SV3, SV4) of each control valve arrangement (SVA1 to SVA6) based on the quadrant-based load case analysis; - Performing a controller synthesis for the quadrant control valve system (V1, V2, V3, V4) based on the synthesized circuit diagram and the role assignment; - Implementing the synthesized circuit diagram of the quadrant control valve system (V1, V2, V3, V4); and - Implementing the synthesized controller in the electronic valve control (C1, C2, C3, C4) of the quadrant control valve system (V1, V2, V3, V4). [2] Method according to claim 1, characterized by that the result of the automated quadrant-based load case analysis maps all load cases (LF1 to LF5) occurring in the hydraulic system (100, 200, 300, 400) and all transitions between the load cases (LF1 to LF5) in a four-quadrant field per hydraulic consumer (12, 20, 30, 32, 34), whereby the four quadrants each map a unique combination of positive or negative load (p) and positive or negative movement (s) of the corresponding hydraulic consumer (12, 20, 30, 32, 34). [3] Method according to claim 1 or 2, characterized bythat the hydraulic system (100, 200, 300, 400) comprises at least two hydraulic consumers (12, 20, 30, 32, 34) which are operated exclusively sequentially, wherein an automated load case analysis is carried out separately for each hydraulic consumer (12, 20, 30, 32, 34). [4] Method according to claim 1 or 2, characterized by that the hydraulic system (100, 200, 300, 400) comprises at least two hydraulic consumers (12, 20, 30, 32, 34) which are also operated in parallel, wherein an automated load case analysis is carried out separately for each hydraulic consumer (12, 20, 30, 32, 34) and additionally an automated load case analysis is carried out for each case in which at least two hydraulic consumers (12, 20, 30, 32, 34) are operated in parallel. [5] Method according to one of the preceding claims, characterized bythat the circuit diagram synthesis is carried out automatically and includes an automated selection of a number of required control valves (SV, SV1, SV2, SV3, SV4) for each control valve arrangement (SVA1 to SVA6). [6] Method according to one of the preceding claims, characterized by that each control valve (SV, SV1, SV2, SV3, SV4) is an electromagnetically operated 2 / 2-way control valve and each control valve arrangement (SVA1 to SVA6) preferably comprises at least two control valves (SV, SV1, SV2, SV3, SV4) and particularly preferably four control valves (SV, SV1, SV2, SV3, SV4). [7] Method according to one of the preceding claims, characterized by that the requirement data of the hydraulic system (100, 200, 300, 400) include measurement and / or simulation data. [8] Method according to one of the preceding claims, characterized by that the process further comprises the following downstream steps: - Reading of sensor data recorded and stored during operation of the quadrant control valve system (V1, V2, V3, V4) and - Optimize the role assignment of the individual control valves (SV, SV1, SV2, SV3, SV4) as well as the synthesized controller based on the recorded and stored sensor data. [9] Method according to claim 8, characterized by that the downstream steps of reading and optimizing are also carried out automatically during operation of the quadrant control valve system (V1, V2, V3, V4). [10] Method according to one of the preceding claims, characterized by that the automated steps of the process are carried out computer-based using machine learning methods. [11] Method according to claim 10, characterized bythat the machine learning methods preferably include convolutional neural networks (CNNs), transformer models, recurrent neural networks (RNNs) and / or knowledge-based methods. [12] Quadrant control valve system (V1, V2, V3, V4) for a hydraulic system (100, 200, 300, 400), wherein the hydraulic system (100, 200, 300, 400) comprises at least one hydraulic consumer (12, 20, 30, 32, 34) which is controlled via the quadrant control valve system (V1, V2, V3, V4), wherein the quadrant control valve system (V1, V2, V3, V4) comprises a control valve arrangement (SVA1 to SVA6) for each hydraulic consumer (12, 20, 30, 32, 34) of the hydraulic system (100, 200, 300, 400) to be controlled, a control valve sensor system and an electronic valve control (C1, C2, C3, C4), wherein the quadrant control valve system (V1, V2, V3, V4) was formed according to a method according to one of the preceding claims. [13] Quadrant control valve system (V1, V2, V3, V4) according to claim 12, characterized by that the quadrant control valve system (V1, V2, V3, V4) further comprises a storage unit (M1, M2, M3, M4) in which the sensor data recorded by the control valve sensors during operation of the quadrant control valve system (V1, V2, V3, V4) are stored. [14] Hydraulic system (100, 200, 300, 400) with at least one hydraulic consumer (12, 20, 30, 32, 34) and a quadrant control valve system (V1, V2, V3, V4) according to claim 12 or 13.

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