Hydraulic Fluid Balancing for Heavy Load Vehicle Pendulum Volume
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Solution Overview
Problem
Heavy-duty transport vehicles with modular hydraulic support systems face challenges in adjusting pendulum volume, leading to potential oil undersupply or overflow, resulting in inefficiencies, increased costs, and operational interruptions due to the need for additional drive units and manual fluid adjustments.
Innovation Solution
A system with a control unit, liquid tank, and hydraulic lines that use a pump device to automatically adjust hydraulic fluid levels based on sensor readings, allowing for flexible positioning and efficient regulation of fluid levels within the tank.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If an additional external hydraulic oil tank is connected to the integrated tank, then the pendulum volume is increased, but the drive unit becomes longer or wider and the longitudinal and transverse inclination are severely restricted
Solution Approach 1:
The additional hydraulic oil tank is nested within the existing drive unit structure, utilizing available space inside the drive unit housing. This allows the pendulum volume to be increased without extending the external dimensions of the drive unit, thereby maintaining flexibility in areas with restricted access or slopes.
2Quantity of substance
If an additional external hydraulic oil tank is connected remotely, then the pendulum volume is increased, but the longitudinal and transverse inclination are severely restricted due to overflow risk
Solution Approach 1:
A fill level sensor is installed in the additional hydraulic oil tank to monitor the fluid level. This sensor provides feedback to the control unit, which automatically activates the pump device to transfer hydraulic fluid from the integrated tank to the additional tank when the fill level drops, and reverses the process when the additional tank becomes too full. This closed-loop control prevents overflow and enables the vehicle to maintain its inclination capabilities while having increased pendulum volume.
3Adaptability or versatility
If the fill level of the hydraulic oil tank is manually adjusted, then the pendulum volume is adapted, but time-consuming operations and environmental contamination risk increase
Solution Approach 1:
The system is equipped with a pump device and control unit that automatically monitor and adjust the hydraulic fluid distribution between the integrated and additional tanks. The fill level sensor continuously monitors the fluid level in the additional tank, and the control unit automatically activates the pump to transfer fluid as needed, eliminating the need for manual intervention and reducing the risk of environmental contamination from manual draining and pumping operations.
4Quantity of substance
If an additional modular drive unit is connected to provide additional pendulum volume, then the pendulum volume is increased, but the drive unit utilization decreases and costs increase
Solution Approach 1:
The additional hydraulic oil tank is designed as a multi-functional component that serves dual purposes: it increases the pendulum volume for height adjustment and simultaneously acts as an auxiliary fuel tank when connected to the fuel tank. This eliminates the need for a separate additional drive unit, reducing system complexity and costs while maintaining the required pendulum volume.
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 enables reliable adjustment of pendulum volume, reducing costs and operational disruptions, allowing for flexible placement and minimizing waiting times, while optimizing drive unit utilization and reducing maintenance costs.
Implementation Method 1
The amount of hydraulic oil remaining in the hydraulic oil tank varies with the amount of oil in the hydraulic support. When the vehicle is fully raised, the amount of oil in the support is at its maximum and the amount in the hydraulic oil tank is at its minimum.
Data Source
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AI summary
A system for balancing hydraulic fluid (3) for a drive unit (22) of a heavy-duty transport vehicle (23), in particular a modular heavy-duty transport vehicle (23), comprising a control unit (1) and a fluid tank (2) with at least one level sensor (4), wherein at least one hydraulic line for establishing a hydraulic connection with the drive unit (22) is arranged on the fluid tank (2), and wherein a pump device (11) for conveying hydraulic fluid (3) through the hydraulic line, which can be actuated via the control unit (1), is arranged. Furthermore, a method for balancing hydraulic fluid (3) and a heavy-duty transport vehicle (23) are described.