Dual Hydraulic Circuit System for Work Vehicle Energy Reduction
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Solution Overview
Problem
Prior hydraulic supply systems in work vehicles are inefficient due to the need to support both high pressure, low volume demands and low pressure, high volume demands simultaneously, often requiring large displacement, high pressure pumps that consume excessive energy and are wasteful, as they must be sized for peak loads that are short-lived and infrequent.
Innovation Solution
The implementation of a dual hydraulic circuit system with separate pumps and pressure storage reservoirs, where one circuit handles high pressure, low volume loads and another handles low pressure, high volume loads, using small low volume pumps and hydraulic accumulators to optimize energy use, allowing for independent operation and reduced power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single pump is sized to support peak power loading for both high pressure control functions and low pressure lubrication/cooling functions, then the system can meet all hydraulic demands simultaneously, but the pump consumes excessive energy (5,000 Watts) and creates energy waste through pressure regulation and overflow dumping
Solution Approach 1:
The hydraulic system is divided into two separate circuits: a high-pressure circuit with a first pump (120) dedicated to power shift transmission control, and a low-pressure circuit with a second pump (150) dedicated to lubrication and cooling. This segmentation allows each pump to be optimized for its specific pressure range, eliminating the need for one oversized pump to handle both functions simultaneously.
Solution Approach 2:
The first hydraulic circuit is designed with multi-functionality to serve both power shift control and lubrication/cooling needs. The circuit includes a first pump, a pressure storage reservoir (accumulator), and a regulator that can deliver hydraulic fluid at different pressure levels to different consumers, allowing one circuit to handle multiple functional requirements.
2Power
If a large displacement high pressure pump is used to deliver aggregate maximum volume and pressure, then the system can satisfy peak demands of both control and lubrication systems, but the regulator must dump extra unused oil to return line causing energy loss
Solution Approach 1:
The system segments hydraulic power delivery into two dedicated pumps, each sized appropriately for its specific function. The first pump handles only the high-pressure control functions with much lower flow requirements, while the second pump handles the low-pressure high-volume lubrication and cooling functions separately, eliminating the need for a large pump that would waste energy through regulation.
Solution Approach 2:
A pressure storage reservoir (accumulator) is introduced as an intermediary element in the first hydraulic circuit. The accumulator stores pressurized hydraulic fluid and can supplement the first pump during peak demand periods, allowing the pump to operate at lower average power levels while still meeting peak pressure and flow requirements.
3Reliability
If the pump is sized for peak power loading to support intermittent high pressure demands, then the system can meet transmission shifting requirements, but the pump operates inefficiently during continuous low pressure operation
Solution Approach 1:
The hydraulic system is segmented into two independent circuits with separate pumps optimized for different operating conditions. The first pump is sized for intermittent high-pressure operation and can be cycled or supplemented by the accumulator, while the second pump handles continuous low-pressure operation efficiently. This eliminates the inefficiency of a single pump operating far from its optimal point during continuous low-demand periods.
Solution Approach 2:
The system dynamics are optimized by allowing the first pump to operate intermittently based on control system demands, while the second pump operates continuously at steady state. The pressure storage reservoir provides dynamic supplementation during peak demands, allowing the first pump to maintain smaller displacement while still meeting peak requirements.
4Use of energy by moving object
If a dual circuit system with separate pumps is implemented, then energy consumption is reduced by 75%, but the device complexity increases with additional components
Solution Approach 1:
While segmentation into two circuits does increase component count, each circuit is simplified by being dedicated to a specific pressure range and function. This functional specialization reduces the complexity of pressure regulation and flow control within each circuit compared to a single complex circuit handling all functions.
Solution Approach 2:
The first hydraulic circuit is designed with multi-functionality to serve both power shift control and lubrication/cooling needs through the pressure storage reservoir and regulator system. This allows one circuit to handle multiple functions that would otherwise require separate systems, partially offsetting the complexity increase from having two circuits.
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 approach reduces energy consumption by approximately 75% compared to traditional systems, as the system can support the same loading tasks with only 1,000 Watts of power instead of the typical 5,000 Watts, while maintaining efficiency and functionality.
Implementation Method 1
a pressure storage reservoir coupled with the first fluid pump, and operable to store a reserve hydraulic fluid
Implementation Method 2
a first fluid pump operable to generate a first hydraulic fluid
Implementation Method 3
a second fluid pump operable to generate a second hydraulic fluid
Data Source
AI summary
A hydraulic supply system provides hydraulic power to functional systems of a work vehicle and includes first and second hydraulic circuits. The first hydraulic circuit includes a first fluid pump operable to generate a first hydraulic fluid, a pressure storage reservoir coupled with the first fluid pump, and a first port coupled with the first fluid pump and with the pressure storage reservoir operable to store a reserve hydraulic fluid. The first port delivers a boost hydraulic fluid from the first circuit for use by the work vehicle to operate a first functional system of the work vehicle. The second hydraulic circuit includes a second fluid pump that generates a second hydraulic fluid, and a second port coupled with the second fluid pump delivers the second hydraulic fluid from the second hydraulic circuit for use by the work vehicle to operate a second functional system of the work vehicle.