Hydraulic Pump Pressure Control to Prevent Working Machine Engine Stall
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Solution Overview
Problem
Off-road and construction machines face engine stalling issues due to hydraulic pump failure or overloading, which is difficult for operators to manage manually, especially inexperienced ones, leading to strain on the engine and hydraulic system.
Innovation Solution
A method and system using electronic and hydraulic logic with sensors and a microcontroller to self-regulate hydraulic pressure and engine speed, providing real-time feedback to operators through audio-visual indicators to prevent engine stalling, and automatically adjusting pump functions if necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual pressure control through joystick is used, then operator can control hydraulic pump pressure, but operator cannot maintain suitable pressure in all pumps simultaneously leading to engine stalling
Solution Approach 1:
The system enables self-service by implementing electronic pressure control that automatically maintains suitable pressure in all hydraulic pumps without requiring continuous manual intervention. The microprocessor-based controller monitors pump pressures and adjusts control valve positions autonomously, allowing the system to regulate itself and prevent engine stalling conditions.
Solution Approach 2:
The system implements feedback by using pressure sensors to continuously monitor hydraulic pump pressures and feeding this information back to the microprocessor controller. The controller processes this feedback data and automatically adjusts control valve positions to maintain pressures within optimal ranges, preventing engine stalling while reducing operator workload.
2Adaptability or versatility
If operator controls multiple pump pressures manually, then machine functions can be operated, but operator error increases and strain on engine and hydraulic system increases
Solution Approach 1:
The system replaces the manual mechanical control system with an electronic control system. Instead of relying on operator manipulation of joysticks and control valves, the invention uses electronic sensors, microprocessors, and electronic control valves to automatically manage hydraulic pump pressures, eliminating operator error and reducing mechanical strain on the engine and hydraulic components.
Solution Approach 2:
The system implements parameter changes by dynamically adjusting control valve positions based on real-time pressure sensor data. The microprocessor controller modifies hydraulic system parameters (pressure, flow distribution) automatically to maintain optimal operating conditions across all pumps, preventing overloading and reducing strain on the engine and hydraulic system while preserving full machine functionality.
3Device complexity
If no pressure monitoring system is used, then system is simpler, but first indication of pressure problem is engine stalling which causes damage
Solution Approach 1:
The system implements preliminary action by proactively monitoring hydraulic pump pressures before conditions lead to engine stalling or component damage. The pressure sensors continuously detect pressure deviations, and the microprocessor controller takes preventive action by adjusting control valves to correct pressure imbalances before they become critical, thereby preventing damage while adding only moderate system complexity.
Solution Approach 2:
The system introduces an intermediary monitoring and control layer between the hydraulic pumps and the engine. Pressure sensors act as intermediaries to detect pressure conditions, and the microprocessor-based control system serves as an intermediary that processes this data and adjusts control valves accordingly, providing early warning and corrective action before engine stalling or damage occurs, justified by the prevention of costly damage.
Data Source
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AI summary
A hydraulic system for a working machine, the system comprising an engine, and an engine speed sensor configured to detect the engine speed; a travel pump configured to actuate a travel actuator, and a travel pump pressure sensor configured to detect the travel pump pressure; a service pump configured to actuate a service actuator, and a service pump pressure sensor configured to detect the service pump pressure; and a micro-controller unit configured to receive input values from each sensor, and configured to determine whether each input value is within a predetermined range where the engine will not stall. The micro-controller unit is configured to provide an output when at least one input value is outside the predetermined range.