Hydraulic Pressure Compensator for Actuator Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Hydraulic systems in heavy machinery experience undesirable pressure fluctuations due to the operation of multiple actuators connected to a common pump, leading to inconsistent actuator movements and potential component failure, and existing solutions increase cost and complexity without precise pressure control.
Innovation Solution
A hydraulic system with a source of pressurized fluid, a tank, and a fluid actuator, featuring a first valve with a movable valve element and a proportional pressure compensating valve to maintain a pressure differential within a predetermined range, ensuring consistent fluid pressure across the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple pressure compensating valves are used to reduce pressure fluctuations, then pressure control is improved, but device complexity and cost increase
Solution Approach 1:
The patent divides the pressure control function into two distinct components: a pressure compensating valve that maintains constant pressure downstream by balancing upstream pressure variations, and a relief valve that limits maximum pressure by diverting excess flow to tank. This segmentation allows each valve to be optimized for its specific function, achieving precise pressure control without requiring multiple complex pressure compensating valves for each actuator line.
Solution Approach 2:
The relief valve serves a dual function: it acts as a safety device to prevent over-pressurization and also functions as a pressure regulator by maintaining maximum system pressure at a predetermined level. This multi-functionality reduces the total number of valves needed in the system, addressing the complexity issue while maintaining reliability.
2Reliability
If pressure compensating valves are added to each actuator line, then pressure fluctuations are reduced, but cost increases
Solution Approach 1:
The patent combines the pressure compensating valve and relief valve into a coordinated system where the relief valve is positioned downstream of the pressure compensating valve. This merging of functions at the system level allows a single relief valve to serve multiple actuator lines, reducing the total component count and cost while maintaining pressure stability across all actuators.
Solution Approach 2:
The pressure compensating valve acts as an intermediary device that isolates downstream actuators from upstream pressure fluctuations. By placing this valve in series with each actuator line, it absorbs pressure variations before they reach the actuators, providing stable operation without requiring expensive pressure sensors or electronic control systems.
3Reliability
If existing pressure control methods are used, then some pressure regulation is achieved, but response time is slow and precision is insufficient
Solution Approach 1:
The patent replaces electronic pressure sensors and servo-controlled valves with a purely mechanical pressure control system using spring-loaded pressure compensating valves and relief valves. The spring mechanisms provide immediate mechanical response to pressure changes, eliminating electronic signal processing delays and achieving faster response times with high precision pressure regulation.
Solution Approach 2:
The pressure compensating valve automatically adjusts downstream pressure by balancing forces between upstream pressure, downstream pressure, and spring force. The relief valve self-regulates maximum system pressure by opening when pressure exceeds the spring-set threshold and closing when pressure drops. This self-service mechanism eliminates the need for external control systems, providing instantaneous pressure regulation response.
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 provides high-response pressure regulation, ensuring consistent actuator performance and protecting hydraulic components with a low-cost, simple configuration, effectively mitigating pressure fluctuations and extending component life.
Implementation Method 1
a proportional pressure compensating valve located to control a pressure of a fluid directed between the source and the first valve
Implementation Method 2
a first valve element movable between a flow passing position, at which fluid from the source flows to the first chamber, and a flow blocking position, at which fluid from the source is blocked from the first chamber
Data Source
AI summary
A hydraulic system for a machine is disclosed. The hydraulic system has a source of pressurized fluid and a fluid actuator with a first chamber. The hydraulic system also has a first valve configured to selectively fluidly communicate the source with the first chamber. The first valve further includes a first element movable between a flow passing, at which fluid from the source flows to the first chamber, and a flow blocking position, at which fluid from the source is blocked from the first chamber and a second element configured to selectively drain a control passageway associated with the first element to cause the first element to move. The hydraulic system further has a proportional pressure compensating valve configured to control a pressure of a fluid directed between the source and the first valve dependent upon the pressure of the control passageway.