Forklift Hydraulic Flow Sensor Calibration for Viscosity Drift

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Solution Overview

Problem

Existing hydraulic systems in mobile work machines, such as industrial trucks, suffer from energy losses and undersupply of hydraulic consumers due to the viscosity dependence of volume flow sensors based on measuring turbines, which are affected by temperature fluctuations and fluid aging, leading to inaccurate volume flow measurements.

Innovation Solution

An electronic control device calibrates the volume flow sensor by comparing its readings with actuation data from hydraulic consumer sensors, using a correction factor adjusted based on temperature and fluid viscosity changes, to ensure accurate volume flow determination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If a volume flow sensor based on a measuring turbine is used to determine the volume flow delivered by the hydraulic pump, then the installation space is reduced and measurement dynamic is improved, but the measurement precision deteriorates due to viscosity dependence of the hydraulic fluid

Engineering Contradiction:
Improveinstallation spaceVSAvoidvolume flow measurement precision
Core Design Contradiction:
Volume of moving objectVSMeasurement precision

Solution Approach 1:

The patent implements a feedback mechanism where the electronic control device continuously monitors the volume flow sensor signals and compares them against expected values based on pump operating conditions. When deviations are detected that indicate viscosity-related measurement errors, the system automatically adjusts the pump control parameters to compensate, thereby maintaining measurement precision without changing the physical sensor structure.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The patent changes the operational parameters of the measuring turbine by adjusting its rotational speed range and measurement scaling factors based on detected hydraulic fluid viscosity conditions. The electronic control device modifies the evaluation parameters of the sensor signals dynamically, allowing the same physical sensor to maintain precision across varying viscosity conditions caused by temperature changes or fluid aging.

Inventive Principle:
Principle #35Parameter changes

2Reliability

If the hydraulic pump is operated with excess hydraulic energy to ensure supply under all operating conditions, then the reliability of consumer supply is improved, but energy losses increase due to throttling

Engineering Contradiction:
Improveconsumer supply reliabilityVSAvoidhydraulic energy loss
Core Design Contradiction:
ReliabilityVSLoss of energy

Solution Approach 1:

The patent transitions from a static pump delivery volume setting to a dynamic adjustment system. The electronic control device continuously adapts the pump's delivery volume based on real-time sensor feedback about actual consumer demands and hydraulic fluid conditions. This dynamic approach allows the system to maintain reliable supply by matching pump output precisely to consumer needs, eliminating the need for excessive energy provision and associated throttling losses.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The hydraulic system implements self-service through automatic regulation. The electronic control device uses feedback from volume flow sensors and consumer status sensors to autonomously adjust pump operation without external intervention. This self-regulating mechanism ensures consumers are supplied with exactly the hydraulic energy they require, preventing both over-supply (which causes energy loss) and under-supply (which compromises reliability).

Inventive Principle:
Principle #25Self-service

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 calibration method minimizes energy losses and prevents undersupply of hydraulic consumers by precisely adjusting the hydraulic pump output to meet consumer demands, even with changing fluid properties.

Implementation Method 1

Volume flow meters based on a measuring turbine, in which the speed of a measuring wheel, for example an impeller, rotating in the hydraulic fluid is measured

Methodology Applied
Scientific EffectMeasuring turbine rotation: Turbine

Implementation Method 2

the measurement result of the volume flow sensor depends on the current viscosity of the hydraulic fluid during the measurement process

Methodology Applied
Scientific EffectViscosity influence: Viscometer

Data Source

PatentEP4368842B1Mobile working machine, in particular industrial truck
Publication Date: 2025.07.23 LINDE MATERIAL HANDLING GMBH
  • EP4368842B1 patent drawing

AI summary

The invention relates to a mobile work machine (1), in particular a forklift truck, with at least one hydraulic consumer (V), wherein a hydraulic pump (5) is provided which supplies the consumer (V) with hydraulic fluid, wherein an electronic control unit (31) is provided which is connected to a flow sensor (30) arranged in a delivery line (8) of the hydraulic pump (5), wherein the electronic control unit (31) is configured to determine the flow rate delivered by the hydraulic pump (5) on the basis of the signal from the flow sensor (30). The control unit (31) is configured to perform a calibration of the flow sensor (30) installed in the work machine (1).