Fall-Back Support Hydraulics With Stop Valve and Hydraulic Store
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Solution Overview
Problem
Existing hydraulic systems for work machines like cranes and cable excavators consume excessive energy due to constant operation of hydraulic pumps, even when the boom is not in use, leading to inefficiency and increased emissions, especially in electric-driven machines with rechargeable batteries.
Innovation Solution
A hydraulic system that includes a stop valve to block the load-bearing cylinder space of the fall-back support cylinder when not in use, allowing the hydraulic pump to supply energy only during active boom movements, and utilizing a hydraulic store to compensate for small movements, thereby reducing energy consumption and maintaining optimal pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hydraulic pump is permanently installed to supply the fall-back support cylinder, then the fall-back support function is reliably maintained, but energy consumption increases due to continuous operation
Solution Approach 1:
The hydraulic pump operates periodically rather than continuously - it is activated only when the stop valve detects a need for fall-back support (when boom angle exceeds threshold). The stop valve opens the hydraulic connection temporarily to provide support force, then closes it when the boom stabilizes, creating an on-demand periodic operation pattern that reduces energy consumption while maintaining reliability.
Solution Approach 2:
The stop valve incorporates an automatic sensing mechanism that detects boom angle position and autonomously controls the hydraulic connection without requiring continuous pump operation. The system self-regulates by opening the hydraulic path only when the boom needs support and closing it when support is no longer required, eliminating the need for permanent continuous pump activation.
2Stress or pressure
If the hydraulic pump is activated continuously, then optimal pressure is always available for boom support, but basic load consumption increases reducing overall efficiency
Solution Approach 1:
The hydraulic pump provides pressure periodically rather than continuously - activation occurs only when the stop valve senses that boom support is needed (when boom angle exceeds the predetermined threshold). The pressure is maintained optimally during these periodic intervals, and the pump remains inactive otherwise, eliminating continuous basic load consumption while ensuring pressure availability when required.
Solution Approach 2:
The continuous pressure maintenance function is extracted and replaced by an on-demand pressure generation system. The stop valve acts as a gate that extracts only the necessary pressure supply moments from the continuous operation, allowing the pump to remain inactive during periods when full pressure is not needed, thereby removing unnecessary energy loss.
3Use of energy by moving object
If the stop valve blocks the load-bearing cylinder space, then energy consumption is reduced, but the system cannot respond to small movements caused by elastic deformation
Solution Approach 1:
The stop valve serves as an intelligent intermediary between the hydraulic pump and the fall-back support cylinder. It selectively mediates the hydraulic connection - blocking it during stable periods to save energy, but opening it when movement is detected to maintain reliability. This intermediary component enables the system to switch between energy-saving and responsive modes based on actual operational needs.
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 requirements for the fall-back support function, minimizing energy consumption and enhancing overall efficiency by providing energy only when necessary, especially during boom extension or installation operations, while maintaining stable pressure and supporting minimal movements.
Implementation Method 1
a hydraulic store (20) connected to the load-bearing cylinder space (18) between the stop valve (16) and the fall-back support cylinder (12)
Implementation Method 2
a stop valve (16) connected between the hydraulic pump (14) and the fall-back support cylinder (12) that can adopt a blocking position and a passage position and by means of which a load-bearing cylinder space (18) of the fall-back support cylinder (12) can be blocked
Data Source
AI summary
A hydraulic system for operating a hydraulic fall-back support of a work machine including at least one hydraulic fall-back support cylinder for tracking and limiting movements of a boom of the work machine and a hydraulic pump by means of which the fall-back support cylinder and at least one further hydraulic consumer can be supplied with hydraulic fluid. A stop valve having a blocking position and a passage position is connected between the hydraulic pump and the fall-back support cylinder, by means of which the stop valve and a load-bearing cylinder space of the fall-back support cylinder is blockable and a hydraulic store connected to the load-bearing cylinder space is provided between the stop valve and the fall-back support cylinder.