Hydraulic Hose Leak Detection via Flow Error Integration
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Solution Overview
Problem
Hydraulic systems in work machines often experience complete system failure due to significant hydraulic fluid loss from leaks, as existing technologies lack effective detection methods for leaks in hoses and valves.
Innovation Solution
A method and system for detecting leaks in hydraulic systems by estimating hydraulic fluid flow rates between control valve stages and actuators, calculating proportional flow rate differences, and generating a leak signal when the integrated flow error exceeds a threshold, utilizing a twin spool valve and electronic controller to isolate leaks and prevent system failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydraulic systems operate without leak detection, then system simplicity is maintained, but complete system failure occurs due to significant hydraulic fluid loss
Solution Approach 1:
The system continuously monitors hydraulic fluid flow rates through sensors and compares actual flow against expected flow patterns. When deviations indicate a leak, the system provides feedback to the controller, which then isolates the affected work circuit by actuating control valves, maintaining system reliability without requiring complete system shutdown
Solution Approach 2:
The hydraulic system is divided into separate work circuits, each with its own leak detection and isolation capability. The control valve assembly is segmented into multiple independently controllable sections, allowing localized isolation of leaks without affecting other circuits, thus maintaining overall system operation
2Loss of substance
If leak detection systems are implemented, then fluid loss is minimized, but system complexity increases
Solution Approach 1:
The system uses the existing hydraulic fluid flow through the normal operation pathways to provide detection information. Flow sensors monitor the fluid as it naturally circulates through the work circuits, eliminating the need for separate detection infrastructure and reducing overall system complexity while minimizing fluid loss through timely leak detection
3Loss of substance
If complete system shutdown is used to prevent further fluid loss, then fluid loss is minimized, but productivity is reduced
Solution Approach 1:
The hydraulic system is divided into separate work circuits with independent isolation capabilities. When a leak is detected in one circuit, only that specific circuit is isolated by actuating relevant control valves, while other circuits continue to operate normally, maintaining productivity while minimizing fluid loss
Solution Approach 2:
Instead of completely shutting down the entire hydraulic system upon detecting a leak, the system applies partial action by isolating only the affected work circuit or hose section. This allows the majority of the system to continue operating at reduced capacity, balancing fluid loss prevention with maintained productivity
Data Source
AI summary
A system and method for detecting a leak in a hose of a hydraulic system having a control valve assembly with first and second work ports in fluid communication with an actuator is disclosed. In one aspect, the method includes estimating a first hydraulic fluid flow rate for fluid flowing from the control valve assembly first work port to the actuator. Another step may be estimating a second hydraulic fluid flow rate for fluid flowing from the actuator to the control valve assembly second work port. In one step, a proportional flow rate difference is calculated between the first and second hydraulic fluid flow rates. Subsequently, a flow error value can be calculated by subtracting the flow rate difference from a predetermined margin value. Where the flow error value integrated over time exceeds a total flow error threshold value, a hydraulic fluid leak signal can be generated.