Hydraulic Pump Segmentation for Fuel Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Hydraulic systems in machines like mining excavators are not optimized for energy efficiency, leading to excessive fuel consumption as all pumps receive the same command, resulting in higher pressurized oil flow than necessary, regardless of the work cycle.
Innovation Solution
A hydraulic system with multiple pumps and circuits where an electronic controller provides independent pump control commands, allowing at least one component to receive exclusive hydraulic flow from a designated pump and another to share flow from a set of pumps, optimizing flow distribution based on the work cycle segment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If all hydraulic pumps receive the same command signal, then the system structure is simple and easy to control, but excessive hydraulic flow is generated leading to high energy consumption
Solution Approach 1:
The hydraulic pump system is segmented into multiple independently controllable pumps, each capable of receiving and executing different control commands. This allows the system to activate only the necessary number of pumps based on actual workload requirements, avoiding the energy waste of running all pumps at full capacity during low-demand operations.
Solution Approach 2:
The control system dynamically adjusts the operation status of individual hydraulic pumps based on real-time machine operating conditions and work cycle segments. The electronic controller modifies pump commands adaptively, transitioning between different operational modes (exclusive flow, shared flow, idle) to optimize energy consumption while maintaining system simplicity.
2Power
If all hydraulic pumps operate at full capacity, then sufficient hydraulic power is available for all functions, but pressurized oil flow exceeds what is necessary for specific tasks
Solution Approach 1:
Different hydraulic pumps are assigned to different hydraulic circuits based on functional requirements. The system provides localized hydraulic power optimization by directing flow from specific pumps to specific circuits only when needed, rather than distributing excess flow from all pumps to all circuits universally. This matches power delivery to actual local demands.
Solution Approach 2:
The system changes the operational parameters of hydraulic pumps dynamically based on work cycle segments. During travel operations, only travel motors receive hydraulic flow; during digging operations, only digging components receive flow. This parameter adjustment ensures hydraulic power matches actual operational needs, reducing energy loss from unnecessary pressurized flow generation.
3Device complexity
If hydraulic flow is shared among multiple components, then system complexity is reduced, but pressure drop losses increase
Solution Approach 1:
The hydraulic system is segmented into distinct circuits with dedicated pumps for critical functions. By separating hydraulic flow paths and assigning specific pumps to specific circuits (exclusive flow assignment), the system eliminates pressure drop losses that would occur if multiple components competed for flow from a single shared source. Each segment operates independently with its own dedicated power source.
Data Source
AI summary
A hydraulic system for a machine includes a plurality of hydraulic component, wherein the hydraulic components include hydraulic actuators and hydraulic motors. The hydraulic system also includes a plurality of hydraulic circuits, and a plurality of hydraulic pumps for supplying hydraulic fluid to the plurality of hydraulic components via the hydraulic circuits. At least one hydraulic component receives hydraulic flow exclusively from a designated one of the hydraulic pumps and at least another, different hydraulic component receives shared hydraulic flow from a flow sharing set of the hydraulic pumps.