Load-Sense Hydraulic Pressure Margin Detection for Actuator Stall
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Solution Overview
Problem
Existing hydraulic systems lack the ability to effectively detect and remedy deadhead or stall conditions in load sense hydraulic systems, which occur when actuators reach their end stops or encounter loads exceeding system pressure capabilities.
Innovation Solution
Implementing pressure sensors and an electronic controller to monitor the pressure margin between pump supply pressure and actuator load pressure, tracking pre-collapse and collapse conditions, and using a predetermined threshold variation to generate deadhead or stall indications, allowing the controller to adjust system operations accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pressure sensors and electronic controllers are added to detect deadhead or stall conditions, then detection capability is improved, but device complexity increases
Solution Approach 1:
The patent implements feedback by using pressure sensors to continuously monitor the pressure margin between pump supply pressure and actuator load pressure, feeding this information back to an electronic controller that compares it against a predetermined threshold to detect deadhead or stall conditions. This feedback mechanism enables automatic detection and remediation without adding complex manual monitoring systems.
Solution Approach 2:
The system performs self-service by automatically detecting deadhead or stall conditions through the pressure margin monitoring and autonomously remediating the condition by adjusting pump displacement or actuator flow, eliminating the need for external intervention or complex diagnostic systems.
2Reliability
If the system continuously monitors pressure margin to detect deadhead or stall conditions, then reliability is improved, but energy consumption increases
Solution Approach 1:
The patent maintains continuous monitoring of the pressure margin through the pressure sensors and electronic controller, ensuring uninterrupted detection capability. This continuous action is justified by the high reliability requirements for detecting deadhead or stall conditions, and the system only consumes additional energy when actual remediation actions are taken rather than continuous high-power operation.
Data Source
AI summary
A load sense hydraulic system includes pressure sensors that provide feedback to an electronic controller to monitor a pressure margin between a pump supply pressure and an actuator meter-in load pressure. Pre-collapse and collapse of the pressure margin (the collapse indicating a deadhead or stall condition of the actuator), can be tracked by the electronic controller to establish a normal operating pressure margin. The established normal operating pressure margin can be assessed by the controller against a current, actual pressure margin based on feedback from the pressure sensors. A pre-determined threshold variation by the actual pressure margin from the normal operating pressure margin provides an indication of deadhead or stall condition to the controller. The controller may then responsively make modifications to the load sense hydraulic system to remedy the deadhead/stall condition.