Hydraulic Pump Subset Control for Variable Flow Demand
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Solution Overview
Problem
Dynamic testing systems face challenges in efficiently generating hydraulic fluid flows that meet rapidly changing demands, while also reducing energy spikes and wear on pump components.
Innovation Solution
The system employs a method to control a hydraulic power unit by selecting unique subsets of hydraulic pumps based on pre-obtained test flow profiles, ensuring that only the necessary pumps are activated to meet flow demands, thereby optimizing energy usage and reducing wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If all hydraulic pumps are activated to meet peak flow demands, then the system can satisfy rapidly changing flow demands, but energy consumption increases and wear on pump components increases
Solution Approach 1:
The system divides the hydraulic pump fleet into multiple subsets and activates only the necessary subset based on real-time flow demand. The controller segments the pumps into different operational groups, activating minimal required pumps during low-demand periods and scaling up to full activation only when peak demand requires it, thereby reducing overall energy consumption while maintaining productivity.
Solution Approach 2:
The system dynamically adjusts the number of active pumps based on real-time flow demand conditions. The controller continuously monitors hydraulic fluid flow demands and transitions pumps between active and inactive states, creating a dynamic operational mode that optimizes energy usage while ensuring adequate flow supply to meet varying productivity requirements.
2Productivity
If all hydraulic pumps are activated to meet peak flow demands, then the system can satisfy rapidly changing flow demands, but wear on pump components increases
Solution Approach 1:
The system segments pumps into rotational subsets where only a portion of the total pump fleet operates at any given time. By cycling through different subsets and keeping some pumps in standby mode, the system reduces cumulative operating hours for each individual pump, thereby reducing wear and extending component life while maintaining the ability to meet peak flow demands when needed.
Solution Approach 2:
The system implements periodic rotation of pump subsets, where different groups of pumps are activated in alternating periods. This periodic action distributes wear more evenly across the pump fleet and reduces continuous operation time for individual pumps, thereby improving reliability and reducing component wear while maintaining overall system productivity.
3Use of energy by moving object
If a subset of hydraulic pumps is activated to reduce energy consumption, then energy efficiency improves, but the system may not meet rapidly changing flow demands
Solution Approach 1:
The system maintains a pool of standby pumps that are pre-configured and ready for immediate activation. When flow demand increases, the controller can rapidly transition from a minimal subset operation to a larger activated subset by engaging pre-prepared standby pumps, ensuring that energy efficiency is maintained during normal operation while the capability to meet rapidly changing flow demands is preserved through pre-positioned resources.
Solution Approach 2:
The controller continuously monitors hydraulic fluid flow demands and uses this feedback to dynamically adjust the number of active pumps. When flow demand exceeds the capacity of the currently active subset, the feedback mechanism triggers activation of additional pumps from the standby pool, ensuring that energy efficiency is optimized during low-demand periods while maintaining the ability to rapidly respond to increasing flow requirements.
Data Source
AI summary
A hydraulic power unit includes a reservoir containing hydraulic fluid, a main output, a pressure sensor, at least one active valve hydraulic pump and at least one passive valve hydraulic pump. A main flow of the hydraulic fluid is discharged through the main output. The pressure sensor includes a pressure signal that is indicative of a pressure of the main flow. Each active valve hydraulic pump is configured to drive a first flow portion of the main flow from the reservoir to the main output when the pressure signal is below a first pressure setpoint. Each passive valve hydraulic pump is configured to drive a second flow portion of the main flow from the reservoir to the main output when the pressure signal is below a second pressure setpoint.