Hydraulic Axis Energy Storage for Peak Power Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In hydraulic axis applications, there is a need to manage power peaks by storing energy during reduced load cycles to supplement the prime mover during high power demands, particularly in scenarios where high energy is required only during actuator extension and low energy during retraction.
Innovation Solution
A closed circuit hydraulic axis with a prime mover, bidirectional hydraulic main pump, differential area actuator, main accumulator, and energy storage accumulator, where the system can switch between conventional and energy storage modes, using control valves to isolate or activate the accumulators and a variable charge pump to store and release hydraulic fluid at varying pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If energy storage accumulator is activated to store energy during reduced load cycles, then power peaks are reduced and energy efficiency is improved, but device complexity increases due to additional accumulators and control valves
Solution Approach 1:
The hydraulic system is segmented into two distinct accumulation pathways: a main accumulator for general pressure management and an energy storage accumulator specifically for recovering energy during reduced load cycles. This segmentation allows independent optimization of each accumulator's function while managing overall system complexity through clear functional separation.
Solution Approach 2:
Control valves serve as intermediaries that regulate fluid flow between the hydraulic circuit, main accumulator, and energy storage accumulator. These intermediary components enable selective activation of energy storage mode without requiring complete system redesign, thus managing complexity while achieving energy efficiency improvements.
2Power
If energy storage mode is activated during actuator extension, then power demand on prime mover is reduced, but control complexity increases due to mode switching requirements
Solution Approach 1:
The system dynamically switches between conventional operation mode and energy storage mode based on real-time operational requirements. During actuator extension, the energy storage mode is activated to reduce power demand on the prime mover, while during retraction, the system returns to conventional mode. This dynamic adaptation allows power optimization without permanent structural complexity.
Solution Approach 2:
The system changes operational parameters by activating or deactivating the energy storage accumulator through control valves. By changing the flow path parameters and pressure management mode rather than physical configuration, the system achieves power reduction while keeping control complexity manageable through parameter adjustment rather than structural modification.
3Loss of energy
If main accumulator is isolated and energy storage accumulator is activated, then energy recovery during retraction is improved, but system reliability may be affected by increased valve operations
Solution Approach 1:
The accumulation function is segmented into two independent systems: the main accumulator handles general pressure stabilization and the energy storage accumulator专门 handles energy recovery during retraction. This segmentation isolates the energy recovery function from the main system, allowing it to operate independently without compromising overall system reliability, even with increased valve operations.
Solution Approach 2:
Control valves act as intermediaries that isolate the main accumulator from the energy storage accumulator during specific operations. By using these intermediary components, the system can activate energy storage mode without directly impacting the main accumulator's reliability, thus protecting system reliability while enabling improved energy recovery.
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 configuration allows for efficient energy storage and release, reducing power peaks during actuator extension by utilizing stored energy, thereby optimizing energy use and reducing the load on the prime mover, especially in applications with varying loads.
Implementation Method 1
a main accumulator connected to the first line via a third line, and a first control valve disposed in the third line between the first line and the main accumulator. In addition, the hydraulic axis includes an energy storage accumulator connected to the first line via a fourth line, and a second control valve disposed in the fourth line between the first line and the energy storage accumulator
Data Source
AI summary
A closed-circuit, self-contained hydraulic axis includes an electric motor, a hydraulic cylinder configured to be connected to a load and a main pump driven by the electric motor to pump hydraulic fluid through the circuit. Pressure connections of the pump are connected to the respective chambers of the cylinder such that the cylinder rod is configured to extend and retract depending on a direction of flow of the hydraulic fluid through the main pump. The hydraulic axis includes a main accumulator connected to the pump via first control valve, an energy storage accumulator connected to the pump via a second control valve, and a charge pump. The hydraulic axis is switchable between a first operating mode that is free of energy storage in the energy storage accumulator, and a second operating mode in which energy is stored in the energy storage accumulator.