Hydraulic Pump Flow Calibration Under Real Pressure Conditions
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Solution Overview
Problem
The dispense flow rate of hydraulic pumps in construction equipment is not accurately calibrated when used under actual conditions, leading to variations in actuator operations due to mismatched pressure conditions between pre-shipment inspections and real-world usage.
Innovation Solution
A hydraulic-pump flow-rate calibration system that includes a hydraulic pump, regulator, flow rate detection device, control device, and calibration device, which calculates actual measurement characteristics to adjust the dispense flow rate based on detected flow rates, using rotation sensors and gyroscope sensors to minimize component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If flow rate characteristics are measured during pre-shipment inspection under predetermined pressure conditions, then inspection efficiency is improved, but measurement precision deteriorates because actual equipment pressure conditions do not match inspection conditions
Solution Approach 1:
The system performs preliminary flow rate characteristic measurements during pre-shipment inspection under standardized pressure conditions, then stores these measurements for later use. This allows efficient batch inspection while preserving the data for subsequent calibration operations that will adjust for actual equipment conditions.
Solution Approach 2:
The calibration device changes the pressure parameter from the predetermined inspection pressure to the actual equipment pressure condition, and recalculates the flow rate characteristics based on this parameter change. This allows the system to maintain inspection efficiency while achieving accurate flow rate characteristics for actual operating conditions.
2Measurement precision
If flow rate characteristics are calibrated after pump installation on actual equipment, then measurement precision is improved, but loss of time increases due to additional calibration operations
Solution Approach 1:
The system uses feedback from the preliminary inspection measurements to automatically calculate and apply calibration adjustments. The calibration device receives the pre-measured flow rate characteristics, compares them with expected values, and automatically generates correction parameters, eliminating the need for manual recalibration and reducing time loss.
Solution Approach 2:
The calibration system performs self-calibration by automatically processing the preliminary inspection data and generating the necessary correction parameters without requiring external intervention or complex manual procedures. This self-service approach minimizes the time required while maintaining high measurement precision.
3Measurement precision
If multiple sensors are added to the hydraulic system for accurate flow rate detection, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The gyroscope sensor, originally intended for other purposes, is made multi-functional by utilizing its detection capabilities for flow rate measurement. This allows the system to achieve accurate flow rate detection without adding dedicated flow sensors, thereby maintaining simplicity while improving measurement precision.
Solution Approach 2:
The system uses an intermediary calculation approach where the calibration device processes data from existing sensors (including the gyroscope) to derive accurate flow rate characteristics. Rather than directly measuring flow rate with dedicated sensors, the system uses intermediate calculations based on available sensor data, reducing hardware complexity while maintaining measurement accuracy.
Data Source
AI summary
A hydraulic-pump flow-rate calibration system includes: a variable capacitance type hydraulic pump that supplies an operating fluid to a hydraulic actuator; a regulator that changes the dispense flow rate of the hydraulic pump according to a flow rate command signal; a flow rate detection device that detects the flow rate of the operating fluid; a control device that outputs the flow rate command signal to the regulator to control the regulator; and a calibration device that calculates an actual measurement characteristic of the dispense flow rate for the flow rate command signal, and performs, on a preset reference characteristic, calibration based on the actual measurement characteristic. The actual measurement characteristic is calculated as a result of the flow rate of the operating fluid being detected by the flow rate detection device during output of a predetermined flow rate command signal from the control device to the regulator.