Hydraulic Control System Flow Correction for Machine Variability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hydraulic control systems for heavy machinery fail to account for machine-to-machine variability, leading to reduced control, performance, and efficiency due to fixed velocity and fluid flow relationships that do not consider system delays and valve behavior.
Innovation Solution
A hydraulic control system that includes a hydraulic actuator, a valve arrangement, an operator input device, and a sensor to determine a desired flow rate, estimate actual flow rates using a system response model, and apply a correction flow rate to achieve the desired velocity, thereby addressing machine-to-machine variability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fixed velocity and fluid flow relationships are used during manufacturing testing, then the control system is simple to implement, but machine-to-machine variability causes reduced control precision and performance
Solution Approach 1:
The system continuously monitors actual fluid flow rate through a flow sensor and compares it to the desired flow rate calculated from the control system. This feedback loop enables real-time detection of deviations caused by machine-to-machine variability, allowing the system to maintain control precision without requiring complex manual calibration for each machine
Solution Approach 2:
The system dynamically adjusts the desired flow rate parameter based on actual operating conditions and measured performance. By modifying the flow rate command in response to detected deviations, the system compensates for machine-specific variations while maintaining the simplicity of the original fixed relationship approach
2Device complexity
If system delays and valve behavior are not considered, then the control system remains simple, but accuracy in achieving desired actuator velocity is reduced
Solution Approach 1:
The system pre-calculates the desired flow rate based on the relationship between control input and expected actuator velocity. By anticipating the required flow before actual movement occurs, the system can compensate for known system delays and valve response characteristics without adding complex real-time prediction algorithms
Solution Approach 2:
Real-time measurement of actual flow rate and actuator velocity provides feedback that reveals discrepancies caused by system delays and valve behavior. This feedback enables continuous correction of the control signal to maintain velocity accuracy despite the inherent system complexities
3Productivity
If correction flow rate is applied based on performance factors, then productivity and efficiency are enhanced, but the control system becomes more complex
Solution Approach 1:
The correction flow rate is determined automatically through continuous feedback from flow sensors and position sensors. The system compares actual performance against desired performance and applies corrections without requiring complex manual intervention or sophisticated control algorithms, thereby enhancing productivity while limiting the increase in system complexity
Solution Approach 2:
The control system performs self-correction by automatically adjusting the flow rate command based on measured performance deviations. This self-service capability allows the system to optimize its own performance without external intervention, improving productivity while maintaining relatively simple control logic
Data Source
AI summary
A hydraulic control system is disclosed. The hydraulic control system may have a hydraulic actuator, a valve arrangement, and an operator input device configured to generate a first signal indicative of a desired hydraulic actuator velocity. The hydraulic control system may also have a sensor configured to generate a second signal indicative of an actual flow rate of fluid entering the hydraulic actuator, and a controller. The controller may be configured to determine a desired flow rate of fluid into the hydraulic actuator based on the first signal; to estimate the actual flow rate based on the desired flow rate, a correction flow rate, and a system response model; and to determine the actual flow rate based on the second signal. The controller may also be configured to make a comparison of the estimated and determined actual flow rates of fluid, and to determine the correction flow rate based on the comparison.