Hydraulic Flow Control for Option Actuator Overload Prevention
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Solution Overview
Problem
Hydraulic machines face challenges in maintaining excellent workability while minimizing damage to option actuators, as existing systems often supply working fluid at insufficient flow rates when multiple manipulators are used, leading to reduced performance and potential actuator damage due to excessive flow rates.
Innovation Solution
The hydraulic machine incorporates a controller that adjusts the flow rates of multiple working fluid supplies, allowing for the combination of flows through a confluence path, ensuring the first supply operates at its capacity and the second supply reduces its output when the combined flow exceeds its capacity, thereby preventing actuator damage and maintaining optimal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the second working fluid supply is controlled to discharge working fluid at a flow rate equal to its capacity, then the flow rate supplied to the option actuator increases, but the option actuator may be damaged due to excessive flow rate
Solution Approach 1:
The controller continuously monitors the flow rate supplied to the option actuator and adjusts the discharge flow rates of the first and second working fluid supplies based on feedback signals. When the combined flow rate approaches the maximum allowable flow rate of the option actuator, the controller reduces the discharge flow rate of the second working fluid supply to prevent excessive flow rate and potential damage, while maintaining optimal productivity within safe limits.
2Productivity
If the first working fluid supply is controlled to discharge working fluid at a flow rate equal to its capacity, then the flow rate supplied to the option actuator increases, but the option actuator may be damaged due to excessive flow rate
Solution Approach 1:
The controller uses feedback from flow rate sensors to monitor the combined discharge flow rate of the first and second working fluid supplies. When the combined flow rate approaches the maximum allowable flow rate of the option actuator, the controller adjusts the discharge flow rate of the first working fluid supply to prevent excessive flow rate and potential damage, while maintaining optimal productivity within safe limits.
3Reliability
If the second flow control valve is moved to cut off the second fluid path, then the option actuator is protected from excessive flow rate, but the speed of the option working device is significantly reduced
Solution Approach 1:
Instead of using a fixed on/off control mechanism, the system employs dynamic flow rate adjustment where the second flow control valve is positioned to allow partial flow based on real-time feedback. The controller continuously adjusts the valve position to maintain the combined flow rate at or below the maximum allowable flow rate of the option actuator, enabling smooth and flexible flow rate control that prevents actuator damage while maintaining optimal working device speed.
4Reliability
If the first working fluid supply and second working fluid supply are controlled to discharge working fluid at flow rates that sum to the maximum allowable flow rate of the option actuator, then the option actuator is protected from damage, but the workability is significantly lowered
Solution Approach 1:
The system employs dynamic flow rate adjustment where the controller continuously monitors the combined flow rate and adjusts the discharge flow rates of the first and second working fluid supplies in real-time. This enables the system to maintain the combined flow rate at or below the maximum allowable flow rate of the option actuator while optimizing the distribution between the two supplies to maintain excellent workability and productivity.
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 ensures that hydraulic machines can operate at higher flow rates required by option actuators during combined manipulator operations, enhancing workability while minimizing the risk of actuator damage by precisely controlling fluid flow rates.
Implementation Method 1
a confluence path connecting the first working fluid path and the second working fluid path to selectively allow working fluid from the second working fluid path to be combined with working fluid in the first working fluid path
Implementation Method 2
a first flow control valve located on the first working fluid path to be movable from a first position to a second position to direct working fluid from the first working fluid path to a first actuator
Data Source
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AI summary
A hydraulic machine comprising a first working fluid supply (110), and a controller (20), the controller calculates a first required flow rate as a function of a first maximum allowable flow rate and a value of a first signal and calculates a third required flow rate as a function of a value of a third signal, and controls the first working fluid supply to discharge working fluid at a flow rate obtained by adding the first required flow rate and the third required flow rate.