Electro-hydraulic Control System Vibration Function
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Solution Overview
Problem
Existing electrohydraulic control systems face inefficiencies and increased costs when attempting to prevent tools from getting stuck during material processing, as existing solutions require additional complex and expensive control valves for vibration functions, which can disrupt the main control valve's operation and complicate coordination.
Innovation Solution
Implementing memory programming to enable a self-controlled vibrating function using the main control valve without additional hydraulic components, by modifying the control current frequency to between 1.0 and 30 Hz for efficient vibration, allowing the tool to vibrate directly via the main control valve, thereby optimizing workflow and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If additional control valves are installed to enable vibration function, then the tool can be shaken to prevent getting stuck, but the device complexity and cost increase significantly
Solution Approach 1:
The main control valve is designed to perform both its primary function of controlling hydraulic fluid flow for tool operation and a secondary function of generating vibration through controlled flow fluctuations. The valve's solenoid actuator can operate in two modes: standard continuous control for normal operation and a vibration mode where it rapidly switches between positions to create shaking motion. This multi-functionality eliminates the need for separate vibration control valves, reducing system complexity and cost while maintaining the ability to prevent tool sticking during material processing
2Loss of time
If additional control valves are installed for vibration function, then the tool can vibrate to save working time, but the cost increases
Solution Approach 1:
The main control valve serves itself by generating vibration function through its own solenoid actuator and control electronics. The control unit detects when the tool is stuck and automatically activates the vibration mode of the existing valve without requiring external vibration-generating components. This self-service approach eliminates the need for additional expensive vibration control valves and their associated electronics, reducing manufacturing costs while still providing the time-saving vibration function to prevent tool sticking
3Productivity
If additional control valves are installed to enable vibration, then the tool can be shaken loose, but the coordination between valves becomes more difficult
Solution Approach 1:
The vibration control function is merged into the main control valve's control logic rather than being implemented through a separate valve. The control unit integrates the vibration function by modifying the control signals sent to the main valve's solenoid actuator. When vibration mode is activated, the control unit rapidly toggles the solenoid state to create flow fluctuations and shaking motion. This merging of functions into a single control point simplifies coordination, as there is only one valve to control rather than multiple valves that need to be synchronized, thereby reducing control complexity while maintaining productivity
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 allows for cost-effective and efficient implementation of a vibrating function that saves working time and improves the work process by using existing main control valves, reducing the need for additional components and simplifying system coordination, while adapting frequency to suit the material being processed.
Implementation Method 1
These main control valves are used to control the direction of movement and optionally load-independent, stepless regulation of the speed of movement of hydraulic consumers
Implementation Method 2
The control current for actuating the main control valve is applied with a dither frequency of between around 40 to 100 Hz, preferably around 55 Hz, in order to prevent overloading of the solenoid actuator, as a result of which the piston valve of the multi-way valve is continuously adjusted
Implementation Method 3
a hydraulic consumer, with which a tool W can be moved in constant direction
Implementation Method 4
controlled, with activated vibration function software for controlling volume flow fluctuations, volume flow fluctuations Q' are superimposed on a volume flow setpoint of the main control valve, so that the tool is vibrated during its movement
Data Source
Figure 1~3
Figure 4~6
AI summary
The system (E) has a central controller attached with a mechanically adjustable tool actuator (6), where a computerized program (Z) is stored in the controller. A magnet actuator of a main control valve is connected with hydraulic cylinders (8, 9) for moving a tool (W). Tool-vibration functional software requirements stored in a memory programming are directly activated by the valve. Volumetric flow fluctuations of the hydraulic cylinders are controllable for performing a vibration function (F) of the tool. The function is activatable by a direct or indirect monitoring sensor system (10).