Hydraulic Accumulator Charge Time for Flow Rate Estimation

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Solution Overview

Problem

Conventional methods for estimating the health and remaining useful life of hydraulic elements rely on expensive sensors and flow measurement devices, which are prone to errors due to sensor drift and require frequent calibration and replacement.

Innovation Solution

A method and system that determine the charge time of a hydraulic accumulator's pressure, calculate the discharging flow rate of the hydraulic element, and estimate its health and remaining useful life using a processor, eliminating the need for frequent sensor calibration and replacement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional sensors or flow meters are used to measure flow rate, then measurement capability is provided, but cost increases and measurement precision deteriorates over time due to sensor drift requiring frequent calibration

Engineering Contradiction:
Improveflow rate measurement accuracyVSAvoidsensor reliability over time
Core Design Contradiction:
Measurement precisionVSReliability

Solution Approach 1:

The patent introduces a hydraulic accumulator as an intermediary component between the hydraulic element and the measurement system. By measuring the charge time of the accumulator (how long it takes to reach upper threshold pressure), the system indirectly determines flow rate without requiring direct flow measurement sensors. This mediator approach eliminates sensor drift issues while providing reliable flow rate information for health assessment

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the conventional sensor-based measurement system with a pressure-based timing system. Instead of using flow meters or sensors to directly measure flow rate, the system uses a pressure sensor to monitor the time required to charge the hydraulic accumulator to a threshold pressure. This mechanical/timing-based approach substitutes for the electronic sensor system, providing more reliable measurements over time

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If expensive sensors and flow meters are used, then flow rate measurement is enabled, but device complexity and maintenance requirements increase

Engineering Contradiction:
Improveflow rate measurement capabilityVSAvoidsensor calibration and replacement requirements
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent extracts the flow rate measurement function from the hydraulic system itself and transfers it to the hydraulic accumulator. By using the accumulator's charge time as the measurement basis, the system removes the need for expensive flow meters and sensors in the hydraulic circuit. The measurement function is taken out and performed by the accumulator's pressure response characteristics

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces expensive, maintenance-intensive sensors and flow meters with a simple pressure sensor and timing mechanism. The pressure sensor is more robust and less prone to drift, and the timing-based measurement approach eliminates the need for frequent calibration and replacement, effectively using a more durable, lower-maintenance solution

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS9556887B2System and method for estimating health and remaining useful life of a hydraulic element
Publication Date: 2017.01.31 CATERPILLAR INC
  • US9556887B2 patent drawing
  • US9556887B2 patent drawing
  • US9556887B2 patent drawing

AI summary

A method for estimating health and remaining useful life of a hydraulic element of a machine is provided. The method includes determining a charge time of a hydraulic accumulator coupled to the hydraulic element in which a current pressure of a hydraulic fluid in the hydraulic accumulator reaches an upper threshold pressure, the current pressure being measured by a hydraulic accumulator pressure sensor coupled to the processor and the hydraulic accumulator. The method includes determining a discharging flow rate of the hydraulic element based upon the determined charge time of the hydraulic accumulator, a health indicator of the hydraulic element based upon a difference between the discharging flow rate and a stored discharging flow rate. The method includes determining a remaining useful life of the hydraulic element based upon the health indicator of the hydraulic element.