Confluence Valve Control for Construction Machinery Flow Rate
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Solution Overview
Problem
Existing confluent flow control devices for construction machines face challenges in precisely manipulating working devices to perform complex operations due to issues like internal leakage, pressure loss, and difficulty in adjusting the open area of confluence valves, leading to inaccurate control and inefficient fluid flow management.
Innovation Solution
A confluent flow control device that includes a pilot pump, first and second variable displacement hydraulic pumps, hydraulic control levers, working device control valves, a confluence valve, and proportional control valves, with a controller that calculates and applies electrical signals to convert pilot pressure into secondary pressures, allowing for precise manipulation of working devices and fluid flow management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a confluence valve is used to allow hydraulic fluid from multiple pumps to join, then complex operations of working devices are enabled, but internal leakage and pressure loss occur leading to inaccurate control
Solution Approach 1:
A pilot pump and proportional control valve are introduced as intermediary components to precisely control the confluence valve's open area. The pilot pump generates pilot pressure that is regulated by the proportional control valve according to control lever signals, enabling accurate modulation of the confluence valve without direct mechanical linkage or imprecise pilot pressure application.
Solution Approach 2:
The system dynamically adjusts the open area of the confluence valve by changing the pilot pressure parameter. The proportional control valve converts electrical control signals into proportional pilot pressure changes, which in turn modulate the confluence valve's opening degree, allowing precise control of the mixed hydraulic fluid flow rate and pressure to multiple working devices.
2Quantity of substance
If the open area of confluence valve is increased to allow more fluid flow, then fluid flow management is improved, but difficulty in adjusting the open area precisely occurs
Solution Approach 1:
The mechanical adjustment system for the confluence valve's open area is replaced with an electro-hydraulic control system. The proportional control valve receives electrical control signals from the controller and converts them into proportional pilot pressure, which precisely modulates the confluence valve's open area. This substitution enables accurate control of hydraulic fluid flow rate without mechanical linkage errors or difficulty in precise adjustment.
3Device complexity
If pilot pressure is applied directly to confluence valve from control lever, then simple control structure is maintained, but pressure loss and internal leakage reduce control reliability
Solution Approach 1:
A pilot pump is introduced as an intermediary component between the hydraulic system and the confluence valve. The pilot pump generates dedicated pilot pressure that is supplied to the proportional control valve, which then regulates the pilot pressure applied to the confluence valve according to control lever signals. This intermediary system eliminates pressure loss and internal leakage issues associated with direct pilot pressure application while maintaining control reliability.
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
The solution enables accurate and reliable manipulation of confluence valves, improving operability and convenience by allowing fluid flows to join seamlessly, and enabling working devices to perform complex operations without interruption, while the proportional control valve outputs a secondary pilot pressure distinct from the control lever signal.
Implementation Method 1
a pilot pump; a proportional control valve disposed on a pilot line between the pilot pump and the confluence valve to convert pilot pressure supplied to the confluence valve by the pilot pump to secondary pressure corresponding to an electrical signal applied to first proportional control valve and applying the converted secondary pressure to the confluence valve
Implementation Method 2
a proportional control valve disposed on a pilot line between the pilot pump and the confluence valve to convert pilot pressure supplied to the confluence valve by the pilot pump to secondary pressure corresponding to an electrical signal applied to first proportional control valve
Implementation Method 3
a confluence valve disposed on the supply passage between the second hydraulic pump and the second working device, upstream of the second working device control valve, wherein the confluence valve, when switched by pilot pressure supplied by the pilot pump, allows a portion of hydraulic fluid discharged from the second hydraulic pump to flow through a confluence passage to join hydraulic fluid discharged from the first hydraulic pump
Data Source
AI summary
Disclosed are a control device for confluence flow rate of a working device and a control method therefor, the control device being capable of minutely operating a working device when a flow rate supplied to the working device is merged or blocked. Provided is a control device for confluence flow rate of a working device for construction machinery according to the present invention, the control device comprising: first and second hydraulic pumps and a pilot pump; first and second hydraulic operating levers; first and second working devices operated by operating oil supplied from the first and second hydraulic pumps; a control valve for the first working device, installed on a supply path between the first hydraulic pump and the first working device; a control valve for the second working device, installed on a supply path between the second hydraulic pump and the second working device; a confluence valve installed on the supply path upstream of the control valve for the second working device; a first proportional control valve installed in a pilot line between the pilot pump and the confluence valve; and a controller for calculating, as electrical signals, pilot pressures applied to the control valves for first and second working devices in proportion to the operation amount of the first and second hydraulic operating levers and thus applying the operated electrical signal to the first proportional control valve.