Hydraulic Compensator Pressure Limiting via Pilot Signal
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Solution Overview
Problem
Existing hydraulic systems face inefficiencies in limiting work port pressure without causing high flow losses, as current methods like work port relief valves and pre-pressure compensated circuits are not optimal for regulating pressure and flow effectively.
Innovation Solution
The proposed solution involves removing work port relief valves and using a compensator to control pressure by limiting the pilot signal pressure, either by reducing pressure on the open side or increasing pressure on the closed side, thereby regulating flow and pressure in the hydraulic circuit through a compensator valve system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If work port relief valves are used to limit pressure, then pressure is controlled, but flow losses increase and efficiency decreases
Solution Approach 1:
The patent introduces a pilot signal as an intermediary control mechanism. Instead of directly controlling the main work port pressure with a relief valve, a pilot relief valve controls a smaller pilot signal pressure that indirectly regulates the main pressure through the compensator valve, reducing energy loss
Solution Approach 2:
The patent changes the control parameter from direct work port pressure control to pilot signal pressure control. By controlling the pilot signal pressure (which is a smaller, secondary pressure), the system achieves main pressure regulation with minimal energy loss
2Stress or pressure
If pre-pressure compensated circuits are used to limit pressure, then pressure regulation is achieved, but system complexity increases
Solution Approach 1:
The patent combines the pressure compensation function and pressure limiting function into a single compensator valve assembly. The compensator valve integrates both flow compensation and pressure regulation capabilities, eliminating the need for separate pressure limiting components
3Stress or pressure
If pressure is limited by releasing through relief valve, then pressure control is achieved, but energy efficiency decreases
Solution Approach 1:
The patent implements a feedback mechanism where the compensator valve continuously monitors the pressure differential across it and adjusts its opening accordingly. When pressure reaches the desired level, the compensator closes, maintaining pressure without continuous energy loss
Solution Approach 2:
The patent extracts the essential control function from the traditional relief valve approach. Instead of using a relief valve that continuously releases pressure, the system uses a compensator valve that selectively opens only when needed, taking out the excessive energy release and replacing it with precise control
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 approach enhances efficiency by minimizing flow losses and effectively controlling pressure and flow in hydraulic systems, preventing damage from excessive pressure and optimizing energy use by controlling the compensator rather than releasing pressure through a relief valve.
Implementation Method 1
A compensator valve system is provided including a valve body, a compensator spool movable within the valve body between a closed position and an open position, a spring urging the compensator spool towards the closed position, and a relief valve having an inlet connected to receive the pilot signal and an outlet to a reservoir. The relief valve is configured to limit the pilot signal pressure to a predetermined maximum level.
Implementation Method 2
The pressure is limited in a particular circuit by controlling and closing the compensator when the desired pressure setting is achieved. As the compensator closes flow will be reduced in the circuit resulting in improved efficiency.
Data Source
AI summary
This disclosure provides for pressure limiting a hydraulic system to a desired pressure value by a particular circuit by controlling and closing the compensator when the desired pressure setting is achieved. Closing the compensator will reduced the pressure head and flow in the circuit resulting in improved efficiency. One illustrated embodiment of the disclosure provides a relief valve in the pilot signal for a compensator. The method relates to limiting the pressure on an open side of the compensator, such that the pressure on the other side closes the compensator thereby limiting the pressure and also flow in the hydraulic circuit. In other words, the pressure on the open side is limited by the relief valve. Thus, the pressure on the other side increases thereby regulating the flow and pressure through the compensator.In another embodiment of the disclosure, instead of reducing the pressure on the open side, the pressure on the closed side is increased, thereby controlling the flow and pressure of the hydraulic circuit. The pressure can be increased by a pump or any other suitable mode.