Electronically Controlled Pressure Valve for Hydraulic Lifting Arms
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Solution Overview
Problem
Hydraulic systems in operating machines, such as telescopic lifts and telehandlers, face inefficiencies in energy usage due to excessive pressure in non-operational steps, leading to increased energy consumption and mechanical stress, especially when transitioning between end strokes of actuators or using tools that do not require high pressures.
Innovation Solution
A control and command assembly with an electronically controlled pressure limiting valve, connected to sensors that detect operating parameters, adjusts the maximum permissible pressure in the hydraulic system to optimize energy use by reducing pressure during non-operational or low-pressure tasks, allowing for undersizing of endothermic motors while maintaining performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the hydraulic system maintains high pressure throughout all operating steps, then the operating machine can maintain performance during high-demand operations, but energy consumption increases during low-demand steps
Solution Approach 1:
The pressure limiting valve is made adjustable and electronically controlled, allowing the maximum pressure in the hydraulic system to be dynamically modified based on actual operating conditions detected by sensors, rather than maintaining a fixed high pressure setting
Solution Approach 2:
The maximum pressure parameter of the hydraulic system is changed dynamically according to operating conditions. The electronic control unit modifies the pressure setting of the limiting valve based on sensor data, adapting the pressure level to match the actual work requirements at different moments
Solution Approach 3:
Sensors detect operating parameters and provide feedback to the electronic control unit, which then adjusts the pressure limiting valve accordingly. This closed-loop control ensures pressure is optimized based on real-time machine state and actual work demands
2Loss of energy
If the endothermic motor is reduced in power to meet environmental regulations, then energy savings are achieved, but maintaining performance becomes more difficult
Solution Approach 1:
The hydraulic system pressure parameter is dynamically adjusted to match actual work demands, ensuring that the reduced-power motor operates only at necessary pressure levels, thereby maintaining performance where needed while achieving energy savings overall
Solution Approach 2:
The system transitions from static high-pressure operation to dynamic pressure adjustment, allowing the motor to deliver high power when required while operating at lower power during non-critical phases, optimizing the balance between performance and energy consumption
3Force
If high pressure is maintained in the hydraulic system during all operations, then sufficient force is available for all work tools, but mechanical stress on moving parts increases unnecessarily
Solution Approach 1:
The maximum pressure parameter is dynamically adjusted according to actual operating conditions and work tool requirements, ensuring sufficient force is available when needed while minimizing mechanical stress during low-demand operations
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 solution reduces energy consumption by limiting pressure in energy-consuming steps, saving fuel or electric charge, and minimizes mechanical stress on moving parts, enabling hybrid machines to maintain performance with reduced motor power.
Implementation Method 1
an adjustable pressure limiting valve configured to limit a maximum pressure of the operating fluid in the valve distributor
Implementation Method 2
at least one sensor configured to detect an operating parameter of the operating machine, preferably of the lifting arm
Implementation Method 3
the pressure limiting valve is an electronically controlled valve that is operatively connected to the electronic control unit
Data Source
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AI summary
A control and command assembly for a lifting arm (13) of an operating machine (10) comprising: - a hydraulic system (30) comprising: ▪ a valve distributor (31) comprising one or more sections (S1,...S4) connectable to respective utilities (131,132,133,134); ▪ an operating fluid supply apparatus (32) comprising a pump (320) adapted to supply the pressurized operating fluid to the valve distributor (31); ▪ an operating fluid discharge tank (T) connected to one or more discharge sections of the respective utilities (131,132,133,134); and ▪ an adjustable pressure limiting valve (35) configured to limit a maximum pressure of the operating fluid in the valve distributor (31); wherein the control and command assembly further comprises: - at least one sensor (411,412,413,414,415) configured to detect an operating parameter of the operating machine (10); and - an electronic control unit (45) operatively connected to the sensor (41,42,43,44); characterized in that the pressure limiting valve (35) is an electronically controlled valve that is operatively connected to the electronic control unit (45) and the electronic control unit (45) is configured to: detect a value of the operating parameter via the sensor (411,412,413,414,415); determine a maximum permissible pressure value in the valve distributor (31) as a function of the value of the detected operating parameter; and set the pressure limiting valve (35) at the determined maximum permissible pressure value.