Hydraulic Pump Torque Distribution for Construction Machinery
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Solution Overview
Problem
Hydraulic systems in construction machinery, particularly excavators, face inefficiencies due to pressure loss and energy wastage, especially when actuators are idle, leading to reduced fuel efficiency.
Innovation Solution
A hydraulic system and control method that directly control actuators using pumps, distributing torque based on weighted values for each operation, adjusting the swash-plate angle of pumps to optimize torque distribution, thereby reducing pressure loss and efficiently utilizing engine torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hydraulic oil is distributed through a main control valve, then the hydraulic system can control multiple actuators, but pressure loss increases and fuel efficiency decreases
Solution Approach 1:
The patent divides the centralized hydraulic control system into multiple independent pump-actuator pairs. Each pump is directly connected to its corresponding actuator, eliminating the need for a centralized control valve. This segmentation removes the pressure loss pathway while maintaining the ability to control multiple actuators independently.
Solution Approach 2:
The patent introduces a control valve at each pump-actuator interface instead of using a centralized main control valve. This distributed intermediary approach allows local flow control while eliminating the energy loss associated with centralized valve passage, as each control valve only handles the flow for its specific actuator.
2Reliability
If pumps continuously drive actuators, then actuators are always ready for operation, but energy is wasted when actuators are in idle state
Solution Approach 1:
The patent implements dynamic torque distribution where the engine torque is dynamically allocated to multiple pumps based on the actual operational needs of each actuator. When an actuator is idle, its corresponding pump receives reduced or zero torque allocation, while operational actuators receive increased torque. This dynamic adjustment maintains actuator readiness while eliminating energy waste during idle periods.
Solution Approach 2:
The patent changes the torque parameter dynamically based on actuator state. The control system monitors the operational state of each actuator and adjusts the torque parameter for each pump accordingly. This parameter change allows the system to transition between different energy consumption states while maintaining the capability for immediate actuator response.
3Ease of operation
If torque is evenly distributed to all pumps, then system is simple to control, but torque cannot be optimized for specific operations
Solution Approach 1:
The patent implements a feedback control mechanism where the control system receives information about the operational state of each actuator and the current torque requirements. Based on this feedback, the system automatically adjusts the torque distribution to each pump to optimize performance for the current operation, while maintaining simple operator input through the manipulating unit.
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 approach reduces pressure loss and improves fuel efficiency by redistributing torque to idle actuators, ensuring that engine torque is utilized effectively without wastage, enhancing overall operational efficiency.
Implementation Method 1
a main hydraulic pump which is driven by transmitted power of the engine to eject hydraulic oil
Implementation Method 2
controlling a swash-plate angle of each pump in accordance with the torque distribution ratio
Data Source
AI summary
The present disclosure relates to a hydraulic system of construction machinery and a method of controlling the hydraulic system. The hydraulic system of construction machinery and the method of controlling the hydraulic system according to the present disclosure assign a weighted value for each operation, preliminarily distribute a (available torque that can be used) value that an engine can provide, through torque weighted values for each operation, and calculate surplus torque and deficient torque by comparing a preliminary distributable torque value to required torque. The surplus torque is provided for an operation in which torque is deemed to be deficient. Thus, the hydraulic system of construction machinery and the method of controlling the hydraulic system according to the present disclosure can sufficiently use available torque that can be used so that an operator can achieve a desired level of performance during the operation.