Synthetically Commutated Hydraulic Machine for Demand-Based Flow Control
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Solution Overview
Problem
Industrial vehicles with multiple hydraulically powered actuators face inefficiencies in energy usage, leading to suboptimal fuel efficiency and increased operational costs due to inadequate hydraulic control systems.
Innovation Solution
A synthetically commutated machine with a prime mover and hydraulic circuit that dynamically allocates working chambers and hydraulic loads, controlling the flow of hydraulic fluid based on demand signals for pressure and flow rate, optimizing energy distribution and reducing the need for additional valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional hydraulic control systems are used with multiple actuators, then the system can operate multiple hydraulic loads, but energy efficiency deteriorates due to inadequate control and suboptimal fuel efficiency
Solution Approach 1:
The hydraulic control system is segmented into multiple independent service groups, where each service group can be independently controlled based on the specific demands of connected hydraulic loads. This segmentation allows optimized energy distribution to different parts of the system rather than treating the hydraulic system as a single unified circuit, thereby improving overall energy efficiency.
Solution Approach 2:
The system dynamically allocates and controls hydraulic fluid flow to different service groups based on real-time demand signals from hydraulic loads. The control system continuously adjusts flow distribution responsive to changing operational requirements, enabling optimal energy efficiency under varying load conditions rather than static control configurations.
2Use of energy by moving object
If hydraulic fluid flow is controlled responsive to demand signals for each service group, then energy efficiency improves, but control system complexity increases
Solution Approach 1:
Each service group is equipped with demand signals from its connected hydraulic loads that automatically indicate required flow and pressure levels. The control system uses these self-generated demand signals to autonomously regulate hydraulic fluid distribution without requiring external manual intervention, achieving improved energy efficiency through automated self-regulating control.
3Device complexity
If the system minimizes the number of valves required, then device complexity reduces, but adaptability deteriorates due to reduced ability to selectively increase service capacity
Solution Approach 1:
The hydraulic control system employs universal control mechanisms that can selectively increase service capacity for different service groups based on operational demands. Rather than requiring dedicated valves for each potential service configuration, the system uses multi-functional control capabilities that can adaptively allocate hydraulic resources to meet varying service requirements, maintaining flexibility with reduced valve count.
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 solution enhances energy efficiency by ensuring hydraulic loads receive sufficient pressure, minimizing the number of valves required and allowing for selective increase in service capacity, thereby reducing fuel consumption and operational costs.
Implementation Method 1
a hydraulic circuit extending between the one or more services and the plurality of hydraulic loads to thereby fluidically connect the one or more services to the plurality of hydraulic loads such that groups of one or more services are fluidically connected to respective groups of one or more hydraulic loads
Data Source
AI summary
An apparatus comprising a synthetically commutated machine with one or more services, a prime mover coupled to the machine, a hydraulic circuit extending between the services and hydraulic loads to fluidically connect the services to the hydraulic loads such that groups of one or more services are fluidically connected to respective groups of one or more hydraulic loads. The apparatus configured such that the flow of hydraulic fluid to or from a group of services of the machine is controlled responsive to measuring a flow rate and/or pressure requirement of the hydraulic loads which are fluidically connected to the services, or receiving a demand signal indicative of a demanded pressure and/or flow rate based on a pressure and/or flow demand of hydraulic loads which are fluidically connected to the services.