Hydraulic Actuator Meter-Out Control for Independent Force and Speed
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Solution Overview
Problem
Existing hydraulic systems for controlling hydraulic actuators in mining machines offer limited control over movement direction, speed, and force, restricting the functionality and productivity of these machines.
Innovation Solution
A hydraulic system with a meter-out control system comprising counterbalance valves and solenoid valves that independently control the movement direction and speed of hydraulic actuators, allowing for precise control of force and movement speed through a control valve assembly, with solenoid valves controlling the counterbalance valves and pressure settings adjustable by a control unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional hydraulic system with a single control valve is used, then the system structure is simple, but the control versatility over movement direction, speed, and force is limited
Solution Approach 1:
The hydraulic control system is segmented into separate functional components: a control valve for direction and speed control, and counterbalance valves for independent force control. This segmentation allows each component to specialize in specific control functions, achieving versatile control over movement direction, speed, and force independently, while using standard off-the-shelf components to avoid excessive complexity
Solution Approach 2:
The control valve assembly is designed to perform multiple functions: controlling movement direction, regulating movement speed, and working in conjunction with counterbalance valves for force control. This multi-functionality approach allows a single control valve to handle various control tasks, reducing the need for separate specialized components for each function
2Measurement precision
If independent control of force and speed is implemented using counterbalance valves and solenoid valves, then control precision is improved, but device complexity increases
Solution Approach 1:
Solenoid valves are introduced as intermediary devices to control the opening pressure of counterbalance valves. These solenoid valves act as mediators between the electrical control system and the hydraulic force control mechanism, enabling precise and independent force control without requiring complex direct control mechanisms on the counterbalance valves themselves
Solution Approach 2:
Manual or mechanical pressure adjustment mechanisms are replaced with electrically controlled solenoid valves that can precisely control counterbalance valve opening pressure through electrical signals. This substitution provides more precise control capability while using standardized electrical components rather than complex mechanical adjustment mechanisms
3Productivity
If meter-out control with actively controlled counterbalance valves is used, then productivity and user-friendliness increase, but system complexity increases
Solution Approach 1:
The counterbalance valves are designed with actively controllable opening pressure that can be dynamically adjusted during operation through solenoid valve control. This dynamic control capability allows the system to adapt to varying operational requirements in real-time, improving productivity and user-friendliness by enabling flexible control of force and speed during machine operation
Solution Approach 2:
The opening pressure parameter of the counterbalance valves is made variable and controllable through solenoid valves, rather than being fixed. This parameter change capability allows independent adjustment of force control characteristics to match different operational demands, enhancing operational efficiency and versatility while using standard controllable valve components
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 provides more versatile and accurate control of hydraulic actuators, enhancing productivity and user-friendliness by enabling independent control of movement direction, force, and speed, while maintaining reliability and cost-effectiveness.
Implementation Method 1
solenoid valves controlling opening pressure of the counterbalance valves
Implementation Method 2
counterbalance valves and solenoid valves controlling opening pressure of the counterbalance valves
Data Source
AI summary
A hydraulic system, mining machine and method of controlling a hydraulic actuator. The hydraulic system (HS) is provided with a control valve (23) for controlling movement direction and speed of a hydraulic actuator (HA) connected to the system. Generated force of the hydraulic actuator is controlled independently relative to the control valve by means of counterbalance valves (Cb1, Cb2) and servo valves (Sv1, Sv2) controlling their opening pressure. The counterbalance valves and the servo valves operate as a meter-out control assembly which controls flow of hydraulic fluid discharged from working pressure spaces (16a, 16b) of the hydraulic actuator. The disclosed system may be implemented to control a mining boom (3) of a mining machine (1).