Hydraulic Soft Start System with Piloted Flow Control
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Solution Overview
Problem
Prior art hydraulic soft start systems are inefficient in using hydraulic fluid, prone to leaks and contamination due to multiple connections, and performance is affected by temperature fluctuations, leading to inconsistent motor engagement and reduced work output.
Innovation Solution
A hydraulic soft start system utilizing a first and second flow restricting orifice and a piloted flow control valve to gradually increase fluid flow to a hydraulic motor, minimizing fluid loss and optimizing pressure application through a two-stage fluid flow approach, reducing the need for multiple connections and enhancing robustness against temperature variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a primary flow control valve is slowly opened to regulate initial pressure and flow to a hydraulic motor, then the motor can be gradually engaged, but fluid pressure and flow are lost during the valve opening process, reducing system efficiency
Solution Approach 1:
The system pre-charges the accumulator to full operating pressure before motor engagement. The flow control valve then only needs to control the rate of pressure transfer to the motor, not build pressure from scratch, eliminating energy loss during pressure development while maintaining gradual engagement capability
2Adaptability or versatility
If multiple separate valves and charging components are used in the hydraulic system, then each component can be independently controlled, but numerous individual connections increase system complexity, cost, and failure rate
Solution Approach 1:
The patent integrates the flow control valve, check valve, and accumulator into a single integrated assembly with internal fluid passages. This consolidation maintains the functional independence of each component while eliminating numerous external connections, reducing complexity and potential failure points
3Ease of operation
If traditional throttled systems are used to control fluid flow, then gradual motor engagement is achieved, but cranking speeds are limited and work output is reduced
Solution Approach 1:
The system dynamically transitions from a controlled flow phase (gradual engagement) to a full flow phase (maximum power). The flow control valve gradually opens to engage the motor, then fully opens to allow maximum fluid flow to the accumulator, enabling full cranking speed and work output once engagement is achieved
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 system achieves efficient hydraulic fluid usage, reduces leaks and contamination, and maintains consistent motor engagement across varying conditions, allowing for faster cranking speeds and improved work output compared to traditional throttled systems.
Implementation Method 1
A first flow restricting orifice is provided in fluid communication with and disposed between the outlet of the first valve and the inlet of the associated hydraulic motor
Implementation Method 2
A second flow restricting orifice is provided in fluid communication with and disposed between the pilot and the inlet of the associated hydraulic motor
Implementation Method 3
A hydraulic pilot for actuating the second flow control valve is provided. The pilot is in fluid communication with the inlet of the associated hydraulic motor
Data Source
AI summary
A hydraulic soft-start system includes a first flow restricting orifice and a flow control valve both being in fluid communication with a pressure source and an inlet of a motor. Also provided is a second flow restricting orifice disposed between a pilot for actuating the flow control valve and the inlet of the motor. A first flow is passed from the pressure source via the first orifice to an inlet of the motor, placing the motor in a partially-actuated state. The flow control valve is actuated after a threshold pressure of the pilot is reached allowing a second flow to pass from the pressure source to the motor inlet. The second flow is higher than the first flow, thereby placing the motor in a fully-actuated state.