Hydraulic Machine Valve Control for Demand-Based Actuator Flow
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Solution Overview
Problem
Industrial vehicles with multiple hydraulically powered actuators face inefficiencies in energy usage, leading to increased fuel consumption and operational costs, as existing hydraulic control systems struggle to optimize the flow and pressure of hydraulic fluid effectively across multiple actuators.
Innovation Solution
The implementation of an electronically commutated hydraulic machine with a rotatable shaft and working chambers, equipped with low-pressure and high-pressure valves, which actively controls the net displacement of hydraulic fluid based on demand signals, optimizing fluid flow and pressure distribution across multiple actuators through a sophisticated hydraulic circuit and control system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional hydraulic control systems are used with multiple actuators, then the system can perform multiple functions, but energy efficiency deteriorates due to inability to optimize fluid flow and pressure distribution
Solution Approach 1:
The hydraulic machine employs dynamically adjustable working chambers whose volume varies cyclically with rotation of the rotatable shaft. The low-pressure and high-pressure valves actively control the net displacement of hydraulic fluid based on real-time demand signals, allowing the system to adapt fluid delivery to actual actuator needs rather than operating at fixed displacement.
Solution Approach 2:
The system changes key hydraulic parameters including fluid displacement volume, pressure levels, and flow rates by controlling valve timing and chamber volume variations. The controller adjusts these parameters in response to demand signals from actuators, optimizing energy efficiency by matching hydraulic output to actual workload requirements.
2Loss of energy
If hydraulic fluid flow and pressure are not optimized, then system operation is simple, but fuel consumption increases
Solution Approach 1:
The hydraulic machine controller receives demand signals from actuators and uses this feedback to adjust the net displacement of hydraulic fluid by controlling low-pressure and high-pressure valves. This closed-loop control optimizes fuel consumption by ensuring hydraulic fluid is delivered only when and where needed, rather than continuously.
Solution Approach 2:
The controller proactively manages hydraulic fluid delivery by predicting and preparing for actuator demands. The cyclic volume variation of working chambers is synchronized with demand signals to ensure optimal fluid pressure and flow are available when actuators require them, reducing energy losses.
3Quantity of substance
If working chambers are not dynamically allocated to actuators, then control system is simple, but hydraulic fluid usage efficiency deteriorates
Solution Approach 1:
The hydraulic machine divides its output into multiple independently controllable working chambers, each capable of being selectively connected to different actuators. This segmentation allows the controller to allocate specific chambers to specific actuators based on real-time demand, optimizing hydraulic fluid usage by directing flow only to active actuators.
Solution Approach 2:
The rotatable shaft with cyclically varying working chambers serves multiple functions: it can drive different actuators at different times, adjust displacement for different load conditions, and maintain system pressure through controlled fluid recirculation. This multi-functionality enables efficient hydraulic fluid usage across varying operational demands.
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 enhances energy efficiency by optimizing hydraulic fluid usage, reducing fuel consumption, and improving the overall performance of industrial vehicles by dynamically allocating working chambers to actuators based on demand, thereby enhancing the control and management of hydraulic fluid flow and pressure.
Implementation Method 1
a hydraulic machine having a rotatable shaft in driven engagement with the prime mover and comprising a plurality of working chambers having a volume which varies cyclically with rotation of the rotatable shaft
Implementation Method 2
each working chamber of the hydraulic machine comprising a low-pressure valve which regulates the flow of hydraulic fluid between the working chamber and a low-pressure manifold
Implementation Method 3
a high-pressure valve which regulates the flow of hydraulic fluid between the working chamber and a high-pressure manifold
Data Source
AI summary
A prime mover and a plurality of hydraulic actuators, a hydraulic machine having a rotatable shaft in driven engagement with the prime mover and comprising a plurality of working chambers, a hydraulic circuit extending between a group of one or more working chambers of the hydraulic machine and one or more of the hydraulic actuators, each working chamber of the hydraulic machine comprising a low-pressure valve which regulates the flow of hydraulic fluid between the working chamber and a low-pressure manifold and a high-pressure valve which regulates the flow of hydraulic fluid between the working chamber and a high-pressure manifold. The hydraulic machine being configured to actively control at least the low-pressure valves of the group of one or more working chambers to select the net displacement of hydraulic fluid by each working chamber on each cycle of working chamber volume, and thereby the net displacement of hydraulic fluid by the group of one or more working chambers, responsive to a demand signal, wherein the apparatus further comprises a controller configured to calculate the demand signal in response to a measured property of the hydraulic circuit or one or more actuators.