Hydraulic Drive System Flow Regulator for Energy Loss Reduction
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Solution Overview
Problem
In load-sensing hydraulic drive systems, energy is wasted due to a constant differential pressure between the discharge pressure of the pump and the load pressure of the actuator, especially during full lever operations of the operating device.
Innovation Solution
The system includes a control valve and a flow regulator that adjust the opening area of the control valve and the discharge flow rate of the pump, maintaining constant differential pressure during partial lever operations and reducing it during full lever operations to minimize energy consumption, using a servo piston and differential pressure regulating valve to control the flow rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the differential pressure between the discharge pressure of the pump and the load pressure of the actuator is kept constant regardless of the operating amount, then the load-sensing control is simple and reliable, but energy is consumed wastefully during full lever operations
Solution Approach 1:
The control valve opening area is made dynamically adjustable based on the operating lever inclination angle. When the inclination angle exceeds the predetermined value, the opening area increases from the reference opening area to a maximum opening area, allowing the differential pressure to decrease and reduce energy consumption during full lever operations while maintaining stable load-sensing control during partial operations
Solution Approach 2:
The system changes the differential pressure parameter from a constant value to a variable value based on the operating lever inclination angle. By adjusting the control valve opening area, the differential pressure is allowed to decrease when the inclination angle is between the predetermined value and the maximum value, thereby reducing energy consumption while maintaining control stability in the normal operating range
2Loss of energy
If the opening area of the control valve is increased during full lever operations, then energy consumption is reduced, but the control valve must respond precisely to the operating lever inclination angle
Solution Approach 1:
A detector is introduced as an intermediary component to accurately detect the inclination angle of the operating lever. The detector provides precise measurement data to the control unit, enabling the control valve to respond accurately to the operating lever position without requiring complex mechanical linkages or direct mechanical coupling
Solution Approach 2:
The mechanical connection between the operating lever and control valve is replaced with an electronic control system consisting of a detector and control unit. The detector electronically senses the lever inclination angle, and the control unit processes this information to adjust the control valve opening area, eliminating the need for precise mechanical positioning mechanisms
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 configuration effectively suppresses energy consumption during full lever operations while maintaining normal load-sensing performance during partial lever operations, achieving efficient energy use without requiring electrical components.
Implementation Method 1
a differential pressure between a discharge pressure of the pump and a load pressure of the actuator is constant
Implementation Method 2
a variable displacement pump connected to the control valve by a supply line
Data Source
AI summary
A hydraulic drive system includes control valve and operating devices, a variable displacement pump, and a flow regulator. When an operating lever inclination angle becomes a value, a control valve opening area becomes a reference. When the operating lever inclination angle maximizes, the opening area maximizes. The flow regulator: until the operating lever inclination angle becomes the value, increases the pump discharge flow rate with the inclination angle, so a differential pressure between pump discharge and actuator load pressures is constant; when the operating lever inclination angle becomes the value, controls the pump discharge flow rate, so a control valve passing flow rate is an actuator maximum flow rate when the differential pressure is constant; and when the operating lever inclination angle is between the value and the maximum, defines a maximum pump discharge flow rate, so the pump discharge flow rate is kept to the actuator maximum flow rate.