Closed-Loop Hydraulic Pump and Valve Control for Precise Pressure
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Solution Overview
Problem
Conventional fluid pumping systems in industrial applications face inefficiencies due to the inability to precisely control flow and pressure, leading to increased energy consumption and complexity, with open-loop systems being prone to contamination and reliability issues.
Innovation Solution
A fluid pumping system incorporating a variable-speed and/or variable-torque pump, proportional control valves, and a controller that synchronizes the operation of the pump and valves to precisely control flow and pressure, forming a closed-loop system for improved efficiency and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a conventional hydraulic pump is run at full speed or constant speed to ensure adequate pressure, then the system maintains required pressure for flow control devices, but energy consumption increases and the pump does not take into account the true energy input requirements of the system
Solution Approach 1:
The patent applies dynamics by transitioning from a fixed-speed pump to a variable-speed pump that can dynamically adjust its rotational speed based on the actual flow and pressure demands of the hydraulic system. The pump motor speed is modulated to match the load requirements, avoiding unnecessary energy consumption while maintaining adequate pressure for flow control devices.
Solution Approach 2:
The patent implements parameter changes by varying the pump's operational parameters (speed and flow rate) according to the system's actual needs. Instead of operating at constant full speed, the pump speed and displacement are adjusted to match the required pressure and flow conditions, optimizing energy efficiency while ensuring adequate pressure delivery.
2Measurement precision
If flow control devices are added to control flow in the system, then flow control precision improves, but system complexity increases and additional hydraulic fluid is required for hydraulic controls
Solution Approach 1:
The patent replaces the traditional hydraulic control system with an electric control system. Instead of using hydraulic actuators and control circuits to operate flow control devices, the system uses electronic controllers and electric motors to precisely control pump speed and valve positioning, thereby reducing hydraulic complexity and fluid requirements while maintaining or improving control precision.
Solution Approach 2:
The patent implements multi-functionality by integrating multiple control functions into a single unified control system. The electronic controller manages both pump speed variation and flow control valve operation, eliminating the need for separate hydraulic control circuits and reducing overall system complexity while achieving precise flow control.
3Reliability
If an open-loop system with a large fluid reservoir is used, then the temperature of hydraulic fluid is maintained and adequate supply is ensured, but the system requires additional components like connecting shafts, hoses, pipes, and fittings that are susceptible to contamination and damage
Solution Approach 1:
The patent applies merging by integrating the pump, motor, and control components into a compact, self-contained unit. This consolidation eliminates the need for extensive external piping, hoses, and connecting components, thereby reducing contamination risks and structural vulnerability while maintaining reliable fluid supply through the integrated design.
Solution Approach 2:
The patent extracts and eliminates unnecessary external components (connecting shafts, hoses, pipes, and fittings) by adopting a direct-drive integrated design. The pump is directly coupled to the motor within a sealed housing, removing the need for external mechanical connections and reducing the system's exposure to contamination and physical damage.
4Device complexity
If the pump is made compact and integrated with the actuator, then system complexity is reduced and reliability is enhanced, but the ability to precisely control flow and pressure may be limited
Solution Approach 1:
The integrated pump maintains precise flow and pressure control by implementing variable-speed operation and adjustable displacement. The pump's operational parameters (speed and volumetric displacement) can be dynamically changed to achieve the required flow and pressure levels, ensuring precise control despite the compact integrated design.
Solution Approach 2:
The compact integrated pump achieves precise control through dynamic adjustment capabilities. The pump motor speed and pump displacement are continuously variable, allowing real-time adaptation to different flow and pressure demands. This dynamic control compensates for the compact size, maintaining precision comparable to larger conventional systems.
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 enables faster and more precise control of fluid flow and pressure, reducing the risk of cavitation and fluid temperature issues, while minimizing system complexity and enhancing reliability by integrating the pump and actuator into a compact, closed-loop configuration.
Implementation Method 1
a pump assembly including a pump to transfer the liquid from the reservoir to the actuator
Data Source
Figure 1
Figure 2
Figure 2A
AI summary
A fluid-driven actuator system includes a fluid-driven actuator and at least one proportional control valve and at least one pump connected to the fluid-driven actuator to provide fluid to operate the fluid-driven actuator. The at least one pump includes at least one fluid driver having a prime mover and a fluid displacement assembly to be driven by the prime mover such that fluid is transferred from the pump inlet to the pump outlet. The fluid-driven actuator system also includes a controller that establishes at least one of a speed and a torque of the at least one prime mover to adjust at least one of a flow in the fluid-driven system to a flow set point and a pressure in the fluid-driven actuator system to a pressure set point and concurrently establishes an opening of the at least one proportional control valve to adjust at least one of the flow to the flow set point and the pressure to the pressure set point.