Crane Actuator Cylinder Valve Layout for Smooth Hydraulic Motion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing control systems for actuator cylinders in hydraulic applications, such as cranes, face issues with fluid-dynamic efficiency due to valve closure and sizing challenges, leading to potential sudden accelerations and increased costs.
Innovation Solution
A control system utilizing a distribution valve with staggered check valves, including a balancing valve and a one-way valve, which allows for controlled fluid flow and pressure equalization, preventing jumps during ascent and descent phases, and optimizing valve sizing to enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single valve is used to control fluid flow in the actuator cylinder, then the system structure is simple, but the valve must be sized according to the maximum flow rate which reduces fluid-dynamic efficiency during partial flow conditions
Solution Approach 1:
The patent divides the single valve function into two separate valves: a first check valve (30) and a second check valve (40) with different sizing. The larger first check valve handles maximum flow conditions, while the smaller second check valve handles partial flow conditions, eliminating the need for an oversized valve and improving fluid-dynamic efficiency.
Solution Approach 2:
The system dynamically switches between different valve configurations based on flow conditions. During initial control phase, both valves operate together; during sustained phase, only the second check valve operates. This dynamic adaptation optimizes efficiency for different operational stages.
2Productivity
If a single large valve is used to handle maximum flow rate, then the valve can accommodate all flow conditions, but it causes sudden accelerations and pressure peaks during control transitions
Solution Approach 1:
The patent segments the flow control function into two valves with different capacities. The first check valve (30) is sized for maximum flow rate to handle high productivity requirements, while the second check valve (40) is smaller and activates during sustained phase to provide stable, controlled flow and prevent sudden accelerations.
Solution Approach 2:
The system performs preliminary control action using both check valves during the initial phase to establish stable pressure conditions before transitioning to the sustained phase where only the second check valve operates, preventing pressure peaks and sudden accelerations.
3Reliability
If the valve always tends to close to prevent pressure peaks, then system safety is improved, but the fluid-dynamic efficiency is sacrificed due to repeated opening and closing
Solution Approach 1:
The patent segments the safety and efficiency functions into two separate check valves. The first check valve (30) handles the initial control phase where safety control is critical, while the second check valve (40) handles the sustained phase where fluid-dynamic efficiency is paramount, allowing it to remain open without causing pressure peaks.
Solution Approach 2:
The system dynamically transitions from a safety-oriented control mode (both valves active) to an efficiency-oriented sustained mode (second valve only). This dynamic operation allows the second check valve to remain open during sustained phase, maintaining fluid-dynamic efficiency while the initial control phase ensures system safety.
4Ease of manufacture
If a single valve is used for all control phases, then the system is simpler and cheaper, but it cannot optimize performance for both initial control and sustained phases
Solution Approach 1:
The patent segments the control function into two valves with different sizing requirements. The first check valve (30) is larger and more expensive but only needs to handle initial control. The second check valve (40) is smaller and cheaper, handling the sustained phase. Together they provide optimized control efficiency while being more cost-effective than a single oversized valve.
Solution Approach 2:
The system changes the active valve configuration based on operational phase. During initial control, both valves are active with specific sizing parameters. During sustained phase, only the second check valve is active with optimized parameters for efficiency, allowing the system to achieve high productivity while managing costs effectively.
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 system effectively prevents sudden accelerations and fluid-dynamic inefficiencies by using a small balancing valve and a larger check valve, ensuring smooth operation and reduced costs through efficient fluid management.
Implementation Method 1
a first check valve (30) positioned along a primary branch (21) of the second supply conduit (21, 22) and configured to allow a flow of fluid coming from the first supply conduit (20) and directed towards the second chamber (12) when a pressure difference between a pressure in P and a pressure in the second chamber (12) exceeds a first predetermined value
Implementation Method 2
a second check valve (40) positioned along a secondary branch (22) of the second supply conduit (21, 22) in parallel with the primary branch (21) and configured to allow a flow of fluid coming from the first supply conduit (20) and directed towards the second chamber (12) when a pressure difference between a pressure in P and a pressure in the second chamber (12) exceeds a second predetermined value
Implementation Method 3
The distribution valve (100) is connected to the first supply conduit (20) and the second supply conduit (21, 22) and is configured to alternately supply one between the first supply conduit (20) and the second supply conduit (21, 22) and discharge the other between the first supply conduit (20) and the second supply conduit (21, 22)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention regards a control system (1000) for an actuator cylinder (10) having a first and a second chamber (11, 12), a piston (13) separating said first chamber (11) from said second chamber (12), said system (1000) comprising: a first supply conduit (20) of said first chamber (11) of said cylinder (10); a second supply conduit (21, 22) of said second chamber (12) of said cylinder (10); wherein said first supply conduit (20) and said second supply conduit (21, 22) are connectable to a distribution valve (100) configured to control a feed operation and a discharge operation of said first supply conduit (20) and said second supply conduit (21, 22); a first check system (30) positioned along said second supply conduit (21) and configured to open a passage for a fluid coming from said distribution valve (100) and directed towards said second chamber (12) if the pressure difference between the pressure of said fluid coming from said distribution valve (100) and the pressure in said second chamber (12) exceeds a first predetermined value, and wherein said first check system (30) is connected to said first supply conduit (20) by means of a first pilot conduit (201), wherein said first check system (30) is configured to open a passage for a fluid coming from said second chamber (12) and directed to said distribution valve (100) when the pressure in said first pilot conduit (201) at said first check system (30) reaches a first predetermined value; said second supply conduit (21) comprises a primary branch (21) along which said first check system (30) is positioned, and a secondary branch (22) parallel to said primary branch (21) and along which a second check system (40, 50) is positioned, wherein said second check system (40, 50) is configured to allow to open a passage for a fluid coming from said distribution valve (100) and directed towards said second chamber (12) along said secondary branch (22) if the pressure difference between the pressure of said fluid coming from said distribution valve (100) and the pressure in said second chamber (12) exceeds a second predetermined value, wherein said first and said second check systems (30, 40, 50) are dimensioned in such a way that a maximum fluid flow which can pass through said second check system (40, 50) is at least twice as large as a maximum fluid flow which can pass through said first check system (30).