Hydraulic System with Supplement Pump for Variable Demand
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Solution Overview
Problem
Current hydraulic systems, particularly those using synthetically commutated pumps, face challenges in cost, size, and energy efficiency, especially when requiring high pressures and high flow rates simultaneously, leading to inefficiencies and increased costs.
Innovation Solution
A hydraulic system comprising a main pump and a boost pump, where the boost pump's output is selectively added to the main pump's output to regulate fluid flow rate according to demand, allowing for efficient high-pressure and high-flow operations without wasting energy by dumping pressurized fluid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a single high-pressure pump is used to provide both high pressure and high flow rate, then pressure requirement is met, but system cost and size increase significantly
Solution Approach 1:
The hydraulic system is divided into two separate pumps: a high-pressure pump (synthetically commutated) and a low-pressure high-flow pump (traditional). Each pump is optimized for its specific pressure range, allowing the system to meet both high pressure and high flow rate requirements without using a single oversized expensive pump. The control unit selectively activates appropriate pumps based on real-time pressure and flow demands.
2Stress or pressure
If a single high-pressure pump is used to provide both high pressure and high flow rate, then pressure requirement is met, but pump size increases
Solution Approach 1:
The system uses two smaller specialized pumps instead of one large general-purpose pump. The high-pressure pump handles pressure-critical operations while the low-pressure pump handles flow-critical operations, reducing the overall system footprint and eliminating the need for a single large expensive high-pressure pump.
3Device complexity
If traditional hydraulic pumps are used for high flow rate at low pressure, then cost is reduced, but high pressure capability is lost
Solution Approach 1:
The system segments pressure handling functions: traditional pumps provide cost-effective high flow at low pressure, while synthetically commutated pumps provide high pressure when needed. This hybrid approach maintains cost effectiveness for flow-critical operations while adding high pressure capability only when required.
4Productivity
If high pressure pump operates at high flow rate continuously, then high flow demand is met, but energy efficiency decreases due to dumping pressurized fluid
Solution Approach 1:
The system dynamically adjusts pump operation based on real-time hydraulic consumer demands. The control unit monitors pressure and flow requirements, activating only the necessary pumps at appropriate power levels. This prevents continuous operation of high-pressure pumps at high flow rates and eliminates energy-wasting dumping of pressurized fluid by matching supply exactly to demand.
Solution Approach 2:
The control unit receives feedback from pressure sensors and flow monitors to dynamically adjust pump activation and power delivery. This closed-loop control ensures pumps operate only when and where needed, optimizing energy efficiency while meeting variable flow and pressure demands.
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 configuration enhances energy efficiency and reduces costs by allowing the system to operate efficiently across a wide range of pressure and flow rate demands, making it suitable for applications like wheel loaders and fork-lift trucks.
Implementation Method 1
The power output of a combustion engine drives a hydraulic pump. The hydraulic fluid, pumped by the hydraulic pump, is led to a hydraulic motor through hydraulic tubes. There, the pressure energy of the hydraulic fluid is converted back to mechanical movement.
Implementation Method 2
The hydraulic fluid, pumped by the hydraulic pump, is led to a hydraulic motor through hydraulic tubes. There, the pressure energy of the hydraulic fluid is converted back to mechanical movement.
Data Source
AI summary
If a hydraulic system has several modes of operation, in particular a mode with a high pressure demand (II) and a mode with a high fluid flow demand (II), the hydraulic fluid pump has to be built with an accordingly high fluid flow output. Such a pump is expensive. Therefore it is suggested, to provide two pumps. I.e. a controllable main pump (2) is provided, which supplies the hydraulic consumer (6) during phases (I) of high pressure demand. During phases (II) of high fluid flow demand, normally, relatively low pressures are sufficient. Therefore, it is suggested to provide a parallel boost pump (9), which supplies the hydraulic consumer (6) in addition to the high pressure pump (2), if a high fluid flow is needed. Excess fluid flow output is avoided by controlling the fluid output flow of main pump 2.