DC Hydraulic Pump Control Without PTO or Proportional Valves
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Solution Overview
Problem
Hydraulic systems in lifting or pushing applications face inefficiencies due to constant pressure maintenance, leading to battery drain and component wear, especially when directional valves operate under full load in an on/off manner, necessitating the need for enhanced modulation without requiring a power take-off (PTO) or proportional valve.
Innovation Solution
A DC-powered hydraulic system with a controller that includes an axis switch and a trigger switch, allowing for variable battery output to the hydraulic pump, enabling controlled pressurized fluid delivery to directional valves, and a handheld controller with joysticks for precise operation, reducing wear and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If constant pressure is maintained in the hydraulic pump, then the hydraulic system is ready for immediate operation, but battery drain increases and component wear accelerates
Solution Approach 1:
The patent applies dynamics by transitioning from constant pressure maintenance to variable pressure control. The DC motor-driven pump adjusts pressure dynamically based on actual hydraulic demand, using feedback from directional valves and flow sensors to modulate motor speed and maintain only the necessary pressure level, thereby reducing energy consumption while ensuring system readiness when needed.
Solution Approach 2:
The patent changes the pressure parameter from constant to variable. By using a DC motor with adjustable speed control, the system modifies the pressure output parameter according to operational requirements, avoiding unnecessary high pressure when cylinders are not in use, thus reducing battery drain while maintaining operational capability.
2Ease of operation
If directional valves operate under full load in an on/off manner, then simple control is achieved, but component wear increases
Solution Approach 1:
The patent applies dynamics by replacing static on/off valve operation with dynamic proportional control. The directional valves are equipped with feedback mechanisms that allow continuous adjustment of flow and pressure, enabling smooth transitions rather than abrupt on/off switching, thereby reducing mechanical wear while maintaining ease of operation through intuitive control interfaces.
Solution Approach 2:
The patent implements feedback control in directional valves to prevent full-load on/off operation. Sensors monitor flow rate, pressure, and valve position, providing real-time feedback that allows the control system to modulate valve opening gradually, avoiding sudden load changes that cause wear, while keeping the control interface simple for the operator.
3Reliability
If a proportional valve is used to throttle pressure, then wear on system parts is decreased, but the requirement for a PTO system increases complexity
Solution Approach 1:
The patent replaces the mechanical PTO system with an electric DC motor system. Instead of using a mechanically driven pump with a proportional valve for pressure throttling, the invention uses an electrically controlled DC motor that can directly adjust pump output through electronic speed control, eliminating the need for mechanical PTO components and reducing overall system complexity while maintaining wear-reduction benefits.
Solution Approach 2:
The patent changes the control method from mechanical throttling via proportional valve to electrical parameter control of the DC motor. By adjusting motor speed and torque parameters electronically, the system achieves pressure control without mechanical wear-prone throttling components, simplifying the system architecture while improving reliability.
4Use of energy by moving object
If a DC motor drives the hydraulic pump with variable output, then energy consumption is reduced, but control system complexity increases
Solution Approach 1:
The patent applies parameter changes by using a DC motor controller that adjusts voltage, current, and speed parameters based on hydraulic demand. The controller receives input from flow sensors and directional valve feedback, dynamically modifying motor operating parameters to match actual system needs, thereby reducing energy consumption while using standardized control components that minimize complexity.
Solution Approach 2:
The patent implements self-service control where the hydraulic system's own feedback signals (flow rate, pressure, valve position) automatically regulate the DC motor output. The controller uses this feedback to self-adjust motor parameters without requiring complex external control systems, reducing energy waste while keeping the control architecture simple and intuitive.
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 provides controlled hydraulic pressure modulation without a PTO or proportional valve, reducing wear and energy consumption by allowing variable battery output and precise joystick control, enhancing operational efficiency and extending component lifespan.
Implementation Method 1
a direct current (DC) hydraulic pump operatively connected to the directional valve... operation of a DC motor driving a hydraulic pump
Implementation Method 2
pressurized hydraulic fluid from the hydraulic pump... providing control over pressurized hydraulic fluid delivered to directional valves
Data Source
AI summary
System and methods for a DC powered hydraulic system capable of providing control over pressurized hydraulic fluid delivered to directional valves without the need for a PTO and/or a proportional valve. The hydraulic system controls the output from a battery to a direct current hydraulic pump.