Hydraulic Flow Regulator for Controlled Load Descent
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Solution Overview
Problem
Hydraulic jacks experience rapid fluid escape when lowering a load, leading to hazardous and uncontrollable descent due to the lack of precise control over fluid flow, especially under full load conditions, where existing release valves have limited resolution and result in uneven lowering speeds.
Innovation Solution
A hydraulic flow regulator that alters fluid flow pathways as an inverse function of pressure drop, utilizing a plunger and spring mechanism with multiple ports to maintain a consistent flow rate across a wide dynamic pressure range, thereby controlling the descent rate of loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a simple release valve is used to allow fluid escape, then the device complexity is reduced and ease of operation is improved, but the manufacturing precision and control resolution deteriorate, causing rapid and uncontrollable fluid escape
Solution Approach 1:
The release valve is segmented into multiple discrete ports (first port, second port, third port) that can be independently opened or closed by the plunger. This segmentation allows for graduated control of fluid flow, providing higher resolution control while maintaining operational simplicity. The plunger can selectively open different ports based on pressure conditions, enabling precise flow regulation without complex mechanisms.
2Productivity
If the release valve is opened to allow fluid escape under full load, then the load can be lowered, but the fluid rapidly escapes causing the load to descend too quickly and potentially hazardously
Solution Approach 1:
The flow regulator dynamically adjusts the fluid flow path based on pressure conditions. Under high pressure (full load), the plunger is forced against the seat to close smaller ports, restricting flow to prevent hazardous rapid descent. As pressure decreases, the plunger gradually opens additional ports, allowing increased flow to maintain productive lowering speed. This dynamic adaptation eliminates the fixed trade-off between safety and productivity.
Solution Approach 2:
The system changes the flow parameters (flow area, flow path) based on pressure conditions. The plunger position, determined by pressure differential, changes which ports are open and to what extent. This parameter change allows the system to maintain safe flow rates under high pressure while achieving higher productivity under lower pressure conditions, preventing hazardous descent while maintaining efficient operation.
3Speed
If the screw valve is moved to control fluid flow, then the load descent can be initiated, but the initial lowering speed is too high causing the vehicle to lurch downwardly
Solution Approach 1:
The flow regulator performs preliminary action by pre-configuring the flow path based on initial pressure conditions before the operator fully opens the release valve. When the release valve is first opened under high pressure, the plunger automatically restricts flow through closed ports, preventing the hazardous lurching descent. This preliminary flow restriction stabilizes the descent from the outset, and then gradually increases speed as pressure equalizes, eliminating the initial instability.
4Device complexity
If the release valve allows rapid fluid escape, then the device complexity is reduced, but the flow rate control precision deteriorates causing uneven lowering speeds
Solution Approach 1:
The release valve is segmented into multiple discrete ports (first port, second port, third port) that can be independently opened or closed by the plunger. This segmentation allows for graduated control of fluid flow, providing higher resolution control while maintaining operational simplicity. The plunger can selectively open different ports based on pressure conditions, enabling precise flow regulation without complex mechanisms.
Solution Approach 2:
The flow regulator is self-regulating, automatically adjusting flow paths based on pressure differential without external control. The plunger responds autonomously to pressure changes, opening or closing ports to maintain consistent flow rates. This self-service mechanism provides precise flow control while keeping the device simple, as no external actuators or complex control systems are needed.
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
The flow regulator ensures a nearly constant flow rate independent of pressure changes, safely managing the descent of loads across a large pressure range, eliminating the risk of uncontrolled rapid descent and enhancing operator safety by maintaining a consistent flow rate regardless of load weight.
Implementation Method 1
a spring biased plunger
Implementation Method 2
altering a flow path of the fluid therethrough as an inverse function of a pressure drop of the fluid across the flow regulator
Data Source
AI summary
A hydraulic jack including a load cylinder, a pump, a release valve and a flow regulator. The pump is configured to provide pressurized fluid to the load cylinder. The release valve is in fluid communication with the pressurized fluid. The flow regulator is configured to alter a flow path of the fluid therethrough as an inverse function of a pressure drop of the fluid across the flow regulator. The fluid regulator being in fluid communication with the release valve.