Hydraulic Regeneration Valve Control for Stable Cylinder Flow
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Solution Overview
Problem
In work equipment, the dry weight energy regeneration flow rate varies significantly based on soil load capacity and attachment attitude, often becoming too high or too low, affecting the hydraulic drive system's efficiency.
Innovation Solution
A regeneration device comprising a regeneration valve, non-return valve, and exhaust valve, which independently control the flow rate of the operating fluid, connected to a hydraulic drive system with a hydraulic pump and directional control valve, allowing for precise adjustment of the regeneration flow rate without passing through the directional control valve, and a control device that calculates and adjusts the discharge flow rate based on pressure differences and valve openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the regeneration flow rate is increased to improve energy reuse efficiency, then the fuel consumption performance improves, but the operating speed control becomes unstable and the flow rate may become excessively high
Solution Approach 1:
The patent divides the flow rate control into two independent control paths: one for operating speed control via the regeneration valve, and another for regeneration flow rate adjustment via the exhaust valve. This segmentation allows each valve to perform its specific function without interfering with the other, resolving the contradiction between energy efficiency and control stability.
Solution Approach 2:
The exhaust valve acts as an intermediary component that adjusts the regeneration flow rate independently of the operating speed control. By introducing this intermediate control element, the system can optimize energy reuse without compromising the stability of the cylinder's operating speed control.
2Reliability
If the regeneration flow rate is decreased to maintain stable operation, then the operating stability improves, but the energy reuse efficiency decreases and fuel consumption worsens
Solution Approach 1:
The independent control paths allow the exhaust valve to optimize regeneration flow rate for energy efficiency without affecting the cylinder's operating stability, which is controlled by the regeneration valve. This segmentation enables both objectives to be achieved simultaneously.
Solution Approach 2:
The system changes the flow rate parameter independently through the exhaust valve while maintaining the operating speed parameter stable through the regeneration valve, allowing optimization of energy efficiency without compromising operating stability.
3Device complexity
If a single valve controls both operating speed and regeneration flow rate, then the device complexity is reduced, but the control precision and ability to maintain optimal regeneration flow rate deteriorates
Solution Approach 1:
The patent segments the control functions into two separate valves: the regeneration valve for operating speed control and the exhaust valve for regeneration flow rate adjustment. This segmentation provides the precision needed for each control function while keeping the overall device design relatively simple.
Solution Approach 2:
The regeneration valve serves the primary function of operating speed control, while the exhaust valve provides the additional function of regeneration flow rate adjustment. This multi-functionality approach allows precise control of both parameters without significantly increasing device complexity.
4Productivity
If the operating speed of the cylinder is increased, then the productivity improves, but the regeneration flow rate becomes too low reducing energy reuse efficiency
Solution Approach 1:
The independent control paths allow the exhaust valve to compensate for changes in regeneration flow rate caused by variations in operating speed. When productivity requires higher operating speed, the exhaust valve can adjust to maintain optimal regeneration flow rate for energy efficiency.
Solution Approach 2:
The system dynamically adjusts the regeneration flow rate through the exhaust valve in response to changes in operating speed, allowing the regeneration process to remain optimized regardless of the cylinder's productivity requirements.
5Measurement precision
If the operating speed of the cylinder is reduced, then the control precision improves, but the regeneration flow rate becomes too high reducing system efficiency
Solution Approach 1:
The separate control paths enable the exhaust valve to reduce the regeneration flow rate when the cylinder operates at lower speeds for high precision control, preventing excessive flow rate that would reduce system efficiency.
Solution Approach 2:
The system changes the regeneration flow rate parameter through the exhaust valve to match the operating conditions, reducing the flow rate when precision control is required and maintaining optimal efficiency regardless of the cylinder's operating speed.
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 stabilizes the regeneration flow rate, improving fuel consumption performance and ensuring stable operation of the hydraulic drive system by adjusting the discharge flow rate according to the regeneration flow rate, preventing excessive flow rates and maintaining efficient energy reuse.
Implementation Method 1
a non-return valve that allows a regenerative flow of the operating fluid from the regeneration valve to the other port of the cylinder and blocks an opposite flow of the operating fluid
Data Source
AI summary
A regeneration device includes: a regeneration valve that controls the flow rate of an operating fluid being drained from one port of a cylinder; a non-return valve that allows a regenerative flow of the operating fluid from the regeneration valve to the other port of the cylinder and blocks an opposite flow of the operating fluid; and an exhaust valve that controls the flow rate of the operating fluid output from the regeneration valve being drained to a tank. The regeneration valve controls the flow rate independently of the exhaust valve.