Hydraulic Pump Derate for Engine Thermal Management
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Solution Overview
Problem
Industrial work machines, such as excavators, face challenges in managing engine temperature, particularly at high altitudes where decreased barometric pressure leads to overheating due to increased hydraulic system demand, which existing systems fail to address effectively.
Innovation Solution
A hydraulic system with a controller that adjusts the flowrate of the hydraulic pump based on engine coolant temperature, derating the flow by up to 10% when the temperature exceeds a set value to reduce engine demand and prevent overheating, utilizing a temperature sensor and lookup table to determine the derate percentage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the hydraulic pump operates at full flowrate to meet hydraulic system demand, then machine performance is maintained, but engine temperature increases and overheating occurs
Solution Approach 1:
The pump flowrate is made dynamically adjustable based on real-time temperature feedback from the coolant system. The controller continuously monitors coolant temperature and modulates the pump displacement to optimize the balance between hydraulic performance and thermal management, transitioning from static full-flow operation to adaptive variable-flow operation.
Solution Approach 2:
The system changes the operational parameter of pump flowrate in response to temperature conditions. When coolant temperature exceeds the threshold, the controller reduces pump displacement and flowrate, thereby decreasing engine load and heat generation. This parameter adjustment resolves the contradiction by allowing full performance when cool and reduced performance when hot.
2Temperature
If the pump flowrate is reduced to lower engine temperature, then overheating is prevented, but machine performance decreases
Solution Approach 1:
The controller implements a closed-loop feedback system by continuously monitoring coolant temperature and using this information to adjust pump flowrate. The temperature sensor provides real-time feedback to the controller, which then modulates the pump displacement accordingly. This feedback mechanism ensures performance reduction occurs only when necessary, maintaining optimal balance between thermal management and productivity.
Solution Approach 2:
The hydraulic system performs self-regulation by using its own temperature condition to determine its operational output. The system serves itself by automatically adjusting pump flowrate based on internal thermal state without external intervention, ensuring that performance is maintained when temperatures are acceptable and automatically derated when temperatures rise.
3Device complexity
If existing hydraulic systems operate without temperature-based flow adjustment, then system simplicity is maintained, but thermal management capability is insufficient
Solution Approach 1:
The controller integrates multiple functions into a single component: it manages normal hydraulic pump control and simultaneously performs thermal management by monitoring coolant temperature and adjusting pump flowrate. This multi-functionality allows the system to maintain simplicity in terms of component count while gaining advanced thermal management capability, as the existing controller is repurposed to handle both operational and thermal control.
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 effectively reduces engine demand and maintains safe operating temperatures while minimizing impact on machine performance, ensuring efficient operation and preventing overheating.
Implementation Method 1
A coolant system is in thermal communication with the engine and includes a temperature sensor
Implementation Method 2
The controller is configured to transmit a control signal to the pump to modify a flowrate of the pump and to adjust the flowrate of the pump in response to a signal from the temperature sensor
Data Source
AI summary
A work machine includes a mechanical arm and a hydraulic actuator coupled to the mechanical arm to move the arm between a first position and a second position. A valve is in fluid communication with the hydraulic actuator for supplying fluid to the hydraulic actuator. A pump is configured to discharge fluid to the valve. An engine is operatively connected to the pump. A coolant system is in thermal communication with the engine and includes a temperature sensor. A controller is in communication with the pump and the temperature sensor. The controller is configured to transmit a control signal to the pump to modify a flowrate of the pump and to adjust the flowrate of the pump in response to a signal from the temperature sensor that a temperature is at or above a set temperature value.