Hydraulic Cylinder Virtual Piston Position Control
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Solution Overview
Problem
Determining the piston position in hydraulic cylinder drives is often costly and economically unfeasible, especially in applications like gas compressors where precise position control is necessary but complex and expensive sensor systems are not attractive.
Innovation Solution
A method that involves providing a dynamic model of the hydraulic cylinder drive, controlling the drive with a control signal, and using sensor-based detection to adjust model parameters, allowing for the calculation of a continuous virtual piston position and precise regulation of the piston position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensor-based detection is used to determine piston position, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent creates a virtual copy of the physical piston position through a dynamic model. Instead of using physical sensors to directly measure position, the system generates a virtual position signal by mapping operating parameters (pressure, flow rate) through a dynamic model that replicates the piston's movement characteristics. This virtual copy provides continuous position information without requiring complex sensor installations.
Solution Approach 2:
The patent replaces mechanical/electrical sensor systems with a computational model-based approach. The dynamic model substitutes physical measurement devices by calculating piston position from readily available operating parameters. This substitution eliminates the need for complex sensor hardware while maintaining measurement precision through mathematical modeling and parameter mapping.
2Measurement precision
If complex sensor systems are installed for precise position control, then measurement precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The virtual model creates a digital representation of piston position that can be generated from existing operational data. This copying approach allows precise position control to be achieved through software modeling rather than physical sensor installation, significantly simplifying the manufacturing and installation process while maintaining measurement precision.
Solution Approach 2:
The system uses its own operating parameters (pressure, flow rate) to determine piston position through the dynamic model. Instead of requiring external sensor systems, the hydraulic system itself provides the necessary data for position determination. This self-service approach eliminates the need for additional sensor installations and simplifies manufacturing.
3Manufacturing precision
If continuous position monitoring is implemented, then regulation precision is improved, but use of energy increases
Solution Approach 1:
The patent replaces energy-consuming physical sensor systems with a computational model that processes existing operational parameters. The dynamic model calculates piston position using pressure and flow rate data that are already being measured for other operational purposes, avoiding the need for additional energy-intensive position sensing hardware while maintaining continuous monitoring capability.
Solution Approach 2:
The operating parameters (pressure, flow rate) used by the dynamic model serve multiple functions: they control the hydraulic system operation and simultaneously provide the data needed for piston position determination. This multi-functionality allows continuous position monitoring without additional energy consumption, as the same measurements serve dual purposes.
Data Source
AI summary
A method for determining a piston position of a piston in a hydraulic cylinder drive includes (i) providing a dynamic model of the cylinder drive, (ii) controlling driving of the cylinder drive with a control signal, (iii) detecting a real piston position of the piston, and (iv) adjusting parameters of the model on the basis of the real piston position. The model maps components of the cylinder drive and outputs a calculated piston position of the piston on the basis of detected operating parameters of the cylinder drive. A method of operating an arrangement having a corresponding hydraulic cylinder drive and a mechanism for implementing the methods are also disclosed herein.