Auto-Commissioning Bulk Modulus Detection in Electro-Hydraulic Valves
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Solution Overview
Problem
Accurately measuring the 'bulk modulus over fluid volume' parameter in hydraulic systems is challenging due to its real-time variation with air entrainment and operating pressure, making direct measurement at nominal operating conditions difficult, especially for advanced mobile valves that require precise control.
Innovation Solution
An auto-commissioning method that automatically detects the bulk modulus over fluid volume parameter by performing an automated test using existing sensors in the advanced mobile valve, which includes pressure and position sensors, without requiring additional hardware or operator input, allowing for reduced setup time and improved valve control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If direct measurement of bulk modulus over fluid volume is performed at nominal operating conditions, then measurement precision is improved, but the complexity of the measurement system increases due to real-time variation with air entrainment and pressure
Solution Approach 1:
The system performs preliminary action by automatically detecting and storing the bulk modulus over fluid volume parameter during system commissioning or initialization, before normal operation begins. This preliminary measurement captures the parameter at nominal operating conditions without requiring real-time adjustments during operation, simplifying the overall measurement system while maintaining precision.
Solution Approach 2:
The valve controller performs self-service by automatically detecting the bulk modulus over fluid volume parameter using its own existing sensors (pressure and position sensors) without requiring external measurement equipment. The controller executes an automated test sequence, processes the data, and stores the parameter internally, eliminating the need for complex external measurement systems.
2Device complexity
If automated test is implemented using existing sensors, then device complexity is reduced, but measurement precision may be compromised without additional specialized sensors
Solution Approach 1:
The existing pressure and position sensors in the valve are made multi-functional by using them for both their primary control functions and for detecting the bulk modulus over fluid volume parameter. The automated test sequence utilizes the pressure sensor to measure pressure changes and the position sensor to detect valve spool position, combining these measurements to calculate the parameter with sufficient precision without requiring specialized measurement sensors.
Solution Approach 2:
The system achieves precise measurement by dynamically tracking changes in pressure and position parameters during the automated test sequence. By measuring the rate of change of pressure with respect to fluid volume (derived from position changes), the system calculates the bulk modulus over fluid volume parameter using the relationship between pressure change, volume change, and the sensor data, achieving accurate detection with standard sensors.
3Measurement precision
If manual operator input is required for parameter detection, then measurement precision is improved through expert judgment, but productivity decreases due to increased setup time
Solution Approach 1:
The automated test sequence implements feedback by continuously monitoring pressure and position sensor data during the test, comparing measurements against expected ranges, and automatically adjusting the test procedure if anomalies are detected. This feedback mechanism ensures measurement precision through systematic validation while maintaining productivity by eliminating manual intervention and reducing setup time.
Solution Approach 2:
The system replaces manual operator judgment and mechanical measurement procedures with an automated electronic control system. The valve controller executes the test sequence automatically, processes sensor data using embedded algorithms, and calculates the parameter without requiring operator input. This substitution of manual processes with automated electronic control maintains measurement precision through consistent algorithmic processing while dramatically reducing setup time and improving productivity.
Data Source
AI summary
Systems and methods for auto-commissioning first and second valve assemblies associated with an actuator in an electro-hydraulic system are disclosed. In one method, a controller performs an automatic test protocol to determine a bulk modulus over fluid volume parameter used by the controller to control the valve assemblies. In one aspect, the test protocol can include pressurizing each side of the actuator to two different pressures with one of the first and second valve assemblies and blocking the other side of the actuator with the other of the first and second valve assemblies. The bulk modulus over fluid volume parameter for each valve assembly can be calculated based on recorded fluid pressures at the actuator and consumed flow at the first and second valve assemblies.