Electro-Hydraulic Load Balancing for Multi-Actuator Pressure Matching

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Solution Overview

Problem

Hydraulic transmission systems face energy loss and low efficiency due to load differences among multiple actuators, requiring pressure compensators that cause throttling loss and low recovery efficiency of potential energy.

Innovation Solution

A hybrid electro-hydraulic load sensing system with a load balancing actuator and control method that adjusts the load sensing pump's output flow and motor direction to compensate for load differences, recovering potential energy into a battery.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If pressure compensators are used to match load pressure for each actuator branch, then load pressure matching is achieved, but throttling loss increases

Engineering Contradiction:

Improveload pressure matchingVSAvoidthrottling loss

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent extracts the pressure matching function from traditional pressure compensators and transfers it to a load balancing actuator. This load balancing actuator actively adjusts the load pressure of one actuator to match others, eliminating the need for throttling-based pressure compensators and reducing energy loss while maintaining reliable pressure matching.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the passive mechanical throttling mechanism of pressure compensators with an active electro-hydraulic load balancing actuator. This substitution enables intelligent pressure regulation through electronic control, replacing the energy-wasting mechanical throttling process with a more efficient active control system.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If traditional load sensing system is used, then system simplicity is maintained, but recovery efficiency of potential energy is low

Engineering Contradiction:

Improvesystem simplicityVSAvoidrecovery efficiency of potential energy

Core Design Contradiction:

Device complexityVSLoss of energy

Solution Approach 1:

The patent converts the previously wasted potential energy during actuator lowering into a beneficial resource by enabling the load balancing actuator to recover this energy and store it in a battery. The energy that was originally lost during the lowering process is now captured and reused, transforming a harmful energy loss into a useful energy source.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent implements an energy recovery mechanism that captures potential energy during actuator lowering operations. The load balancing actuator recovers this energy through regenerative braking and stores it in a battery, preventing energy discarding and enabling reuse during subsequent operations.

Inventive Principle:

Principle #34Discarding and recovering

3Adaptability or versatility

If load sensing pump supplies oil to multiple actuators based on maximum load pressure, then all actuators can be powered, but energy loss increases due to load difference

Engineering Contradiction:

Improvemulti-actuator power supplyVSAvoidenergy loss due to load difference

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The patent implements a feedback control mechanism where the load balancing actuator continuously monitors the load pressures of multiple actuators and actively adjusts to eliminate pressure differences. This feedback loop ensures that each actuator receives the precise pressure it needs rather than being subjected to the maximum load pressure of all actuators, significantly reducing energy loss while maintaining the ability to power multiple actuators simultaneously.

Inventive Principle:

Principle #23Feedback

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

Reduces throttling loss and improves energy efficiency by balancing load pressures across actuators, recovering potential energy, and optimizing power consumption.

Implementation Method 1

The load balancing actuator recovers a throttling loss, caused by a load difference between the actuators, and potential energy, generated in a process that the hybrid actuator drives the load to move, into the battery

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS20250347299A1Hybrid electro-hydraulic load sensing system and control method thereof

Publication Date: 2025.11.13 CHONGQING UNIV

AI summary

A hybrid electro-hydraulic load sensing system and a control method are provided. A hybrid actuator of the hybrid electro-hydraulic load sensing system includes a second hydraulic actuator and a load balancing actuator. A battery is connected to a power source through a first inverter and the load balancing actuator through a second inverter. The power source is connected to a load sensing pump, the load sensing pump is connected to a first hydraulic actuator through a first control valve and connected to a second hydraulic actuator through a second control valve, and a first pressure sensor and a second pressure sensor are disposed at an inlet and an outlet of the second hydraulic actuator respectively. A control device is connected to the first pressure sensor, the second pressure sensor, a third pressure sensor, a motor of the load balancing actuator and one oil control assembly.