Hydraulic Pressure Limiting Control for Energy-Saving Material Pumps
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Solution Overview
Problem
Existing hydraulic drive systems for construction material pumps lack efficient energy management, leading to high power consumption and inefficient operation due to fixed pressure settings, which do not adapt to varying operating conditions.
Innovation Solution
A hydraulic drive system with an electrically controllable pressure limiting valve unit and an electrical control unit that automatically adjusts the limit pressure based on user-demanded operating parameters, allowing for demand-dependent energy consumption and adaptive power management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a fixed pressure setting is used in the hydraulic drive system, then the system structure is simple and reliable, but the energy consumption is high and the system cannot adapt to varying operating conditions
Solution Approach 1:
The patent applies dynamics by replacing the fixed pressure setting with a dynamically adjustable pressure limiting valve unit. This valve can vary the limit pressure according to actual operating conditions, allowing the hydraulic system to adapt its pressure output in real-time. The control unit receives signals about operating parameters and automatically adjusts the pressure limiting valve, transforming a static system into a dynamic one that optimizes energy consumption while maintaining simplicity through automated control.
Solution Approach 2:
The patent implements parameter changes by modifying the pressure parameter of the hydraulic system. The pressure limiting valve unit changes the limit pressure value based on operating conditions such as pump output, hydraulic motor speed, or power consumption requirements. This parameter adjustment allows the system to operate efficiently across different loading conditions without requiring a completely complex redesign, balancing energy optimization with system simplicity.
2Use of energy by moving object
If the limit pressure is reduced to save energy, then the power consumption decreases, but the pressure may become insufficient for certain operating conditions
Solution Approach 1:
The patent employs feedback control through the control unit that continuously monitors operating parameters such as pump output, hydraulic motor speed, or power consumption. Based on this feedback information, the control unit automatically adjusts the pressure limiting valve unit to maintain appropriate pressure levels. This feedback mechanism ensures that pressure is reduced only when sufficient for current operations, preventing reliability issues while achieving energy savings during lower-demand periods.
Solution Approach 2:
The dynamic adjustment capability of the pressure limiting valve unit allows the system to respond to changing operational requirements in real-time. When operating conditions demand higher pressure, the valve increases the limit pressure accordingly; when conditions allow, it reduces pressure to save energy. This dynamic behavior resolves the contradiction by making pressure sufficiency conditional on actual needs rather than fixed, maintaining reliability while enabling energy optimization.
3Productivity
If an electrically controllable pressure limiting valve unit is added for automatic pressure adjustment, then the energy efficiency improves, but the device complexity and initial cost increase
Solution Approach 1:
The patent replaces manual or mechanical pressure adjustment mechanisms with an electrically controllable pressure limiting valve unit. This substitution allows for automated, precise pressure regulation based on electronic control signals from the control unit. The electrical control system can process multiple operating parameters and make rapid adjustments, achieving superior energy efficiency compared to mechanical systems, while the modular electronic control architecture keeps the added complexity manageable.
Solution Approach 2:
The control unit serves multiple functions: it monitors various operating parameters (pump output, hydraulic motor speed, power consumption), processes this information, and controls the pressure limiting valve unit. This multi-functional approach consolidates control capabilities into a single device, reducing the overall system complexity despite adding electrical control components. The universal control unit can adapt to different operating conditions and requirements, justifying the added component through its versatile functionality.
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 reduces energy consumption by dynamically adjusting pressure settings in response to operating conditions, optimizing energy use and maintaining efficient pump operation.
Implementation Method 1
The pressure limiting valve unit (6, 24) is designed for the automatic, variable or changeable or closed-loop-controllable setting in particular of a, in particular of at least one, limit pressure, in particular of a limit pressure value or limit pressure magnitude, of hydraulic fluid of at least one section of the hydraulic circuit within a pressure range
Implementation Method 2
The feed pump (2) is designed for automatically feeding hydraulic fluid into the hydraulic circuit (101)
Implementation Method 3
The control unit (27) is designed to automatically control the pressure limiting valve unit (6, 24) in a manner dependent on at least one user-demanded operating parameter, in particular an operating parameter value or operating parameter magnitude, of the hydraulic drive system
Data Source
AI summary
A hydraulic drive system for a construction material pump has a hydraulic circuit for hydraulic fluid, a feed pump which is designed to feed hydraulic fluid into the hydraulic circuit, at least one controllable pressure-limiting valve unit, which is designed for variable adjustment of a limit pressure of hydraulic fluid of at least one portion of the hydraulic circuit within a pressure range, and a control unit. The control unit is designed to control the pressure-limiting valve unit according to at least one operating parameter of the hydraulic drive system and/or according to the hydraulic fluid in such a way that the pressure-limiting valve unit adjusts the limit pressure of the portion of the hydraulic circuit.