Boom Regeneration Motor Control for Construction Machine Fuel Efficiency
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Solution Overview
Problem
Construction machines face reduced fuel efficiency due to the regeneration motor unnecessarily increasing the load on the engine when not performing regeneration operations, leading to inefficient energy use.
Innovation Solution
A construction machine with a regeneration system that includes a regeneration motor, pilot pump, pilot line, regeneration connection line, on/off valve, and control device to manage hydraulic fluid flow and pressure, optimizing the operation rate of the regeneration motor by controlling the swash plate angle of the regeneration pump and using an accumulator to store energy for efficient use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the regeneration motor is connected to assist the engine during regeneration operations, then energy recovery efficiency is improved, but when the regeneration motor does not perform regeneration operations, it unnecessarily increases the load on the engine, reducing fuel efficiency
Solution Approach 1:
The patent applies dynamics by making the connection between the regeneration motor and engine conditional rather than fixed. The control device dynamically controls the connection state based on operating conditions (boom descent detection, hydraulic pressure levels), allowing the system to transition between connected and disconnected states. This resolves the contradiction by enabling energy recovery when beneficial while avoiding unnecessary load when not needed, thus improving both energy recovery efficiency and fuel efficiency.
2Productivity
If the regeneration motor operates continuously to recover energy, then potential energy of the boom is utilized, but the regeneration motor applies unnecessary load on the engine when not performing regeneration operations
Solution Approach 1:
The patent implements feedback control where the control device continuously monitors operating conditions (boom position, hydraulic pressure in the head side of the boom cylinder) and adjusts the connection state accordingly. When the boom is descending and hydraulic pressure indicates available energy, the regeneration motor connects to assist the engine. When conditions are not favorable for regeneration, the connection is disconnected. This feedback mechanism ensures high energy recovery rate when applicable while minimizing fuel consumption by avoiding unnecessary operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration improves overall energy use efficiency by increasing the operation rate of the regeneration motor, minimizing unnecessary load on the engine and enhancing fuel efficiency during regeneration operations.
Implementation Method 1
a regeneration line which is connected to the head side of the boom cylinder and through which hydraulic fluid discharged from the head side of the boom cylinder moves when the boom descends
Implementation Method 2
a pilot pump which generates a pilot pressure; a pilot line through which pilot hydraulic fluid discharged from the pilot pump moves
Implementation Method 3
using an accumulator to store energy for efficient use
Data Source
AI summary
A construction machine according to an exemplary embodiment of the present invention includes: an engine; a boom cylinder which is divided into a head side and a rod side; a regeneration line through which hydraulic fluid discharged from the head side of the boom cylinder moves when the boom descends; a regeneration motor which is connected with the regeneration line and is operated, and assists the engine; a pilot pump which generates a pilot pressure; a pilot line through which pilot hydraulic fluid discharged from the pilot pump moves; a regeneration connection line which connects the pilot line and the regeneration line; an on/off valve installed in the regeneration connection line; and a control device which closes the on/off valve when a pressure of the pilot line drops below a predetermined pressure or the hydraulic fluid discharged from the boom cylinder is supplied to the regeneration motor.