Hydraulic Control Unit for Load-Free Start-Up in Work Vehicles
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Solution Overview
Problem
Existing hydraulic work vehicles face challenges in load-free starting and energy efficiency due to the need for manual operator intervention and complex safety switches, which hinder the implementation of automatic start-stop systems and result in unnecessary power loss and component costs.
Innovation Solution
A hydraulic work vehicle equipped with sensors to detect operating parameters and a control unit that compares these parameters with target rest states, allowing for an automated start-up process without load, enabling the switching off of unused drive trains and ensuring energy efficiency through a controlled start-stop function.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a bypass is used to return flow rate pressurelessly to enable load-free start-up, then starting pressure is reduced, but energy is lost due to unused flow
Solution Approach 1:
The control unit acts as an intermediary between the pump and the actuator, managing the startup sequence by temporarily decoupling them. During the startup period, the control unit prevents control signals from reaching the actuator while the pump accelerates, then gradually couples them once minimum speed is reached, avoiding both bypass energy loss and direct load startup issues
2Reliability
If a safety switch is implemented to prevent actuator power during start-up, then operator protection is improved, but operation becomes more complex and time-consuming
Solution Approach 1:
The control unit automatically manages the startup protection function without requiring manual operator intervention. It self-regulates by monitoring pump speed and automatically enabling/disabling actuator control signals, replacing complex manual safety switch systems with an automated electronic control mechanism
3Reliability
If the drive unit is operated at base speed after starting before actuators are ready, then actuators are protected from premature power, but energy consumption increases and time is lost
Solution Approach 1:
The control unit performs preliminary action by pre-accelerating the pump to minimum operating speed before enabling actuator control. This ensures the hydraulic system is ready to immediately respond to actuator commands once enabled, eliminating the need for prolonged base speed operation and reducing energy consumption
4Use of energy by moving object
If automatic start-stop systems are implemented to save energy, then energy efficiency is improved, but start-up problems recur when systems are restarted
Solution Approach 1:
The control unit implements feedback by continuously monitoring pump speed and using this information to determine when to enable actuator control. This closed-loop control ensures that every startup sequence (including restarts after stop functions) automatically follows the correct sequence, maintaining reliability while enabling energy-saving start-stop operation
Data Source
Figure 1
AI summary
A hydraulic work vehicle with a work tool is proposed, wherein at least one tool holding device is provided for holding the work tool, wherein a hydraulic unit comprising at least one pressure generating device is provided for actuating and/or pressurizing the tool holding device and/or the work tool and/or the drive element, wherein at least one control unit (11) has at least one controllable hydraulic control element (7, 8) and at least one operating element (13) for manual operation/actuation by an operator, which at least partially improves the disadvantages of the prior art.According to the invention, this is achieved by providing at least one sensor for detecting an actual operating parameter of the pressure generating device and/or the control element and/or the hydraulic unit, and by providing a comparison unit for comparing the actual operating parameter with a rest/target operating parameter of a rest state of the pressure generating device (4) and/or the control element (13) and/or the hydraulic unit, wherein a start-up time is provided between the rest state and the operating state of the pressure generating device (4) for starting the pressure generating device (4) up to a start-up speed of the rotary axis, and that the control unit (11) is designed as a control unit (11) for generating an inactive standby state of the tool holding device and/or the working tool and/or the drive element during the start-up time.