Forklift Hydraulic Pump Switching for Pressure-Flow Efficiency
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Solution Overview
Problem
Hydraulic systems in forklift trucks with multiple adjustment functions struggle to achieve optimal efficiency and minimize noise emissions due to the use of a single hydraulic pump that cannot meet the varying requirements of different functions.
Innovation Solution
A hydraulic system with two distinct hydraulic pumps, each optimized for different operating pressures and flow rates, is connected via a piping system and controlled by a control device to selectively use one or both pumps based on the specific requirements of each adjustment function, optimizing efficiency and noise emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single hydraulic pump is used for multiple adjustment functions, then the device complexity is reduced, but the efficiency and noise emission cannot be optimized for all functions
Solution Approach 1:
The hydraulic system is segmented into two independent pumps (first hydraulic pump and second hydraulic pump), each responsible for specific adjustment functions. This segmentation allows each pump to be optimized for its designated functions, resolving the contradiction between system simplicity and operational efficiency.
Solution Approach 2:
The hydraulic piping system dynamically connects different pumps to different adjustment functions based on operational requirements. The system can selectively activate the first pump for high-pressure functions, the second pump for high-flow functions, or both pumps simultaneously, optimizing efficiency for each operational state.
2Device complexity
If a single hydraulic pump is used for multiple adjustment functions, then the device complexity is reduced, but noise emissions increase due to suboptimal pump selection
Solution Approach 1:
The hydraulic system is divided into two specialized pump units, allowing noise optimization for each pump type. The first pump can be selected for low-noise high-pressure applications while the second pump handles high-flow applications, reducing overall system noise emissions.
Solution Approach 2:
Different pump types with different noise characteristics are selected based on the specific parameters of each adjustment function. The system changes operational parameters by selecting which pump operates, matching pump characteristics to functional requirements to minimize noise.
3Speed
If different pump speeds are used to achieve required flow rates, then flow rate requirements are met, but efficiency varies across different operating conditions
Solution Approach 1:
The system dynamically selects between two pumps with different speed-efficiency characteristics. Each pump operates in its optimal efficiency range for specific flow rate requirements, eliminating the efficiency losses that would occur if a single pump had to operate across all speed ranges.
Solution Approach 2:
The system changes the operational parameter of pump selection based on required flow rate. By having two pumps with different displacement volumes and efficiency characteristics, the system can match pump parameters to flow rate requirements, maintaining high efficiency across varying operational conditions.
4Stress or pressure
If high operating pressure is required for certain adjustment functions, then force requirements are met, but efficiency is compromised when using a pump optimized for different pressure ranges
Solution Approach 1:
The hydraulic system is segmented into a first pump optimized for high-pressure applications and a second pump optimized for lower-pressure high-flow applications. This segmentation allows each pump to operate at its optimal pressure range, maintaining efficiency across different adjustment function requirements.
Solution Approach 2:
The system changes the operational parameter of pump selection based on required operating pressure. By selecting the appropriate pump for each pressure requirement, the system maintains high efficiency whether high pressure or high flow rate is the primary requirement.
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
The system ensures efficient operation and reduced noise emissions by matching the appropriate hydraulic pump to the specific demands of each function, enhancing performance and reducing unnecessary noise.
Implementation Method 1
A key aspect of hydraulic system design is selecting a suitable hydraulic pump to power the hydraulically operated components
Data Source
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AI summary
The invention relates to a forklift truck (2) comprising a hydraulic system (10) and at least one hydraulically operated component (30), as well as a method for operating a hydraulic system (10) of the forklift truck (2). The hydraulic system (10) comprises a first hydraulic pump (11), a second hydraulic pump (12), and a hydraulic line system (15). The hydraulic line system (15) is designed and configured to connect the hydraulically operated component (30) selectively either exclusively to the first hydraulic pump (11), exclusively to the second hydraulic pump (12), or simultaneously to both the first hydraulic pump (11) and the second hydraulic pump (12). The first hydraulic pump (11) has a maximum efficiency at a first flow rate (102) and a first operating pressure (101). The second hydraulic pump (12) has a second maximum efficiency at a second flow rate (102) and a second operating pressure (101).The first operating pressure (101) is greater than the second operating pressure (101) and/or the first volume flow rate (102) is smaller than the second volume flow rate (102).