Hydraulic Control Device for Construction Machine Boom Energy Regeneration
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Solution Overview
Problem
Construction machinery fails to effectively regenerate boom energy due to hydraulic motor abnormalities, leading to inefficient energy utilization during boom operations.
Innovation Solution
A hydraulic control apparatus and method that includes an accumulator, hydraulic pump, pressure sensor, and control unit to detect hydraulic motor failures by calculating volume changes and flow rates, allowing for controlled operation and energy regeneration without the need for additional sensors, using a variable displacement hydraulic motor and regeneration valve unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a regeneration device with hydraulic motor is added to regenerate boom energy, then energy efficiency is improved, but system complexity and risk of malfunction increase
Solution Approach 1:
The hydraulic motor is designed to automatically detect its own operational status through software calculation by comparing accumulator volume change with hydraulic motor flow rate. When malfunction is detected, the system automatically switches to normal operation mode without requiring additional sensors or manual intervention, thereby maintaining energy efficiency while managing system complexity through self-diagnosis
Solution Approach 2:
The system implements feedback control by continuously monitoring the relationship between accumulator pressure changes and hydraulic motor flow rate. The control unit uses this feedback to determine motor status and adjust system operation accordingly, enabling dynamic optimization of energy regeneration while maintaining safety
2Reliability
If additional sensors are added to detect hydraulic motor failures, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The hydraulic motor system performs self-diagnosis by using existing sensors (pressure sensor in accumulator, flow rate sensor on hydraulic motor) to calculate operational parameters. The control unit compares calculated volume change from accumulator with actual flow rate through the hydraulic motor, enabling failure detection without requiring additional dedicated sensors for motor status monitoring
Solution Approach 2:
The control unit acts as an intermediary that processes data from existing sensors to infer motor status. Instead of directly monitoring motor health with specialized sensors, the system uses the relationship between accumulator pressure changes and hydraulic motor flow rate as an intermediate indicator to detect motor malfunction, reducing sensor requirements while maintaining reliability
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
Enables determination of hydraulic motor failures through software calculation, preventing energy regeneration device malfunction and alerting operators for timely repairs, thus optimizing energy regeneration and reducing design modifications.
Implementation Method 1
an accumulator to accumulate a high-pressure hydraulic oil discharged from a boom cylinder for driving a boom of the construction machinery
Implementation Method 2
a hydraulic pump connected to the accumulator and driven by the high-pressure hydraulic oil
Implementation Method 3
a pressure sensor configured to detect a pressure of the accumulator
Implementation Method 4
a hydraulic motor and configured to control operations of the accumulator and the hydraulic motor
Data Source
AI summary
A hydraulic control apparatus for construction machinery, includes an accumulator to accumulate a high-pressure hydraulic oil discharged from a boom cylinder for driving a boom of the construction machinery, a hydraulic pump connected to the accumulator and driven by the high-pressure hydraulic oil, a pressure sensor configured to detect a pressure of the accumulator, and a control unit connected to the accumulator and the hydraulic motor and configured to control operations of the accumulator and the hydraulic motor, and having a determiner that receives a pressure value of the accumulator and number of revolution of the hydraulic motor to determine whether or not the hydraulic motor fails when the hydraulic oil accumulated in the accumulator is supplied to the hydraulic motor.