Battery-Powered Hydraulic Rescue Unit With Relief Valve Feedback
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Solution Overview
Problem
Existing portable, battery-operated hydraulic units for rescue tools face inefficiencies in energy use, leading to high noise and heat emissions, and structural complexity, which affects portability and longevity.
Innovation Solution
A portable, battery-operated hydraulic unit with a pressure relief valve that returns hydraulic fluid to a tank when maximum pressure is reached, detected by a state detection mechanism, reducing engine speed to mitigate power loss, noise, and heat, and utilizing existing components for detection to minimize added weight and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a pressure relief valve is used to release excess hydraulic pressure when maximum pressure is reached, then the hydraulic system can prevent over-pressurization, but this results in hydraulic power loss, high noise emissions, and high heat emissions
Solution Approach 1:
The patent implements a feedback control system where a pressure sensor continuously monitors hydraulic pressure and provides real-time data to a control unit. When the pressure reaches a predetermined threshold, the control unit automatically adjusts the hydraulic pump's operation or activates a pressure relief mechanism, creating a closed-loop control system that maintains pressure within optimal ranges without excessive energy loss
Solution Approach 2:
The patent employs dynamic pressure regulation where the hydraulic pump's delivery pressure and flow rate are continuously adjusted based on actual system demands and pressure conditions. This dynamic operation allows the system to operate at variable speeds and pressures rather than maintaining constant high pressure, reducing energy waste while ensuring maximum pressure is available when needed
2Strength
If a pressure relief valve is used to release excess hydraulic pressure, then the hydraulic system can prevent over-pressurization, but this results in high noise emissions
Solution Approach 1:
The feedback control system detects pressure thresholds and triggers controlled pressure relief actions only when necessary, avoiding continuous or excessive pressure relief operations that would generate high noise levels
Solution Approach 2:
The patent replaces traditional mechanical pressure relief valves that generate high noise through sudden pressure release with an electronically controlled hydraulic system that can modulate pressure relief in a more controlled and quieter manner, or use alternative pressure management strategies
3Strength
If a pressure relief valve is used to release excess hydraulic pressure, then the hydraulic system can prevent over-pressurization, but this results in high heat emissions
Solution Approach 1:
The feedback control system monitors pressure and temperature conditions, adjusting pump operation to maintain pressure within safe limits while minimizing unnecessary pressure relief cycles that would generate excessive heat
Solution Approach 2:
The dynamic operation of the hydraulic pump allows it to operate at optimal efficiency points, reducing energy waste and heat generation while still being capable of reaching maximum pressure when required by the system
4Use of energy by moving object
If load-sensing systems are used to optimize hydraulic pump flow rate delivery, then battery power utilization can be improved, but the system complexity increases
Solution Approach 1:
The patent implements a feedback control system where a pressure sensor continuously monitors hydraulic pressure and provides real-time data to a control unit. When the pressure reaches a predetermined threshold, the control unit automatically adjusts the hydraulic pump's operation or activates a pressure relief mechanism, creating a closed-loop control system that maintains pressure within optimal ranges without excessive energy loss
Solution Approach 2:
The control unit performs multiple functions including pressure monitoring, pump control, and safety management, consolidating what would otherwise require multiple separate components into a single integrated system that optimizes battery power usage without proportionally increasing complexity
5Use of energy by moving object
If load-sensing systems are used to optimize hydraulic pump flow rate delivery, then energy consumption can be reduced, but the system lifespan decreases due to wear and tear
Solution Approach 1:
The feedback control system enables precise pressure management, activating pressure relief or pump adjustment only when necessary, thereby reducing the frequency and intensity of wear-inducing operations while maintaining energy efficiency
Solution Approach 2:
The dynamic operation allows the hydraulic system to operate in smoother, more controlled transitions rather than abrupt on/off cycles, reducing mechanical shock and wear on components while maintaining optimal energy consumption
6Power
If electronic control means are used to regulate motor speed and hydraulic pressure, then power output can be controlled, but the device weight increases
Solution Approach 1:
The control unit performs multiple functions including pressure monitoring, pump control, and safety management, consolidating what would otherwise require multiple separate components into a single integrated system that optimizes battery power usage without proportionally increasing complexity
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 enhances energy efficiency, reduces operator stress, and extends the service life of the hydraulic unit while maintaining sufficient power for rescue operations with reduced noise and heat emissions.
Implementation Method 1
a pressure relief valve which is arranged such that when a maximum pressure is reached in at least one of the pressure lines, the hydraulic fluid is returned to the hydraulic tank via the pressure relief valve
Implementation Method 2
at least one hydraulic pump; an electric motor for driving the at least one hydraulic pump
Implementation Method 3
at least one battery pack
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a portable, battery-operated hydraulic power unit (1) for hydraulic rescue tools (4), in particular for spreading and/or shearing tools, and to a method for operating such a hydraulic power unit (1). The invention comprises a control device (13), at least one hydraulic pump (11), at least one first and one second pressure line (16, 23) which are coupled to a pressure outlet (15) of the hydraulic pump (11), a hydraulic tank (21), at least one battery pack, and at least one electric motor (12). Furthermore, a pressure relief valve (22) is configured such that, when a maximum pressure is reached in at least one of the pressure lines (16, 23), hydraulic fluid (17) is returned to the hydraulic tank (21) via the pressure relief valve (22) and a return line (27) coupled to it.Furthermore, a pressure relief valve status sensing device (29) is configured to detect the activation of the pressure relief valve (22). The control device (13) is configured to reduce the motor speed of the electric motor (12) as a result of the detection of the activation of the pressure relief valve (22).