Method for preventing and detecting coolant discharges from complex hydraulic systems
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Solution Overview
Problem
Existing filling systems for hydraulic systems, particularly in the automotive industry, face challenges in limiting coolant discharge during failures or accidents, preventing harmful explosive atmospheres, protecting hydraulic circuits from excessive pressures, preventing coolant discharge from relief valves, and diagnosing leaks, while also meeting stringent safety and explosion protection requirements.
Innovation Solution
The method involves dividing coolant-carrying circuits into small volumes with stop valves and relief valves, using check valves to decouple clusters, and integrating pressure sensors for continuous leak detection, which reduces the need for additional gas warning sensors and enhances leak detection sensitivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coolant-carrying circuits are divided into small volumes with stop valves and relief valves, then coolant discharge quantities are limited and explosion protection requirements are reduced, but device complexity increases
Solution Approach 1:
The coolant-carrying circuit is divided into multiple small-volume clusters, each equipped with stop valves and relief valves. This segmentation limits the maximum discharge quantity in case of failure and reduces explosion protection requirements, while the modular structure manages the added complexity through standardization.
Solution Approach 2:
An accumulator is introduced as an intermediary component to receive coolant discharged from relief valves. This prevents direct discharge into the environment and allows for controlled management of pressure releases, maintaining system safety while managing the complexity of additional components.
2Measurement precision
If pressure sensors are integrated for continuous leak detection, then leak detection sensitivity is enhanced and gas warning sensors are reduced, but device complexity increases
Solution Approach 1:
Pressure sensors are used to detect leaks by monitoring pressure changes in the closed clusters, replacing or supplementing traditional gas warning sensors. This mechanical/physical measurement approach provides continuous monitoring with high sensitivity while reducing the need for multiple gas detection devices.
Solution Approach 2:
The existing pressure measurement equipment in the hydraulic system is utilized for dual purposes: normal system operation monitoring and leak detection. This self-service approach enhances leak detection capability without requiring entirely separate sensing systems, thereby managing complexity.
3Object-generated harmful factors
If clusters are decoupled using check valves and pressure is removed into accumulators, then relief valve activation is prevented and coolant discharge is limited, but device complexity increases
Solution Approach 1:
Pressure is extracted from the individual clusters and transferred to a common accumulator through check valves. This prevents excessive pressure buildup in any single cluster that would trigger relief valves, thereby preventing harmful coolant discharge while using the accumulator as a pressure reservoir.
Solution Approach 2:
The accumulator serves as a pre-prepared pressure buffer that can absorb pressure surges before they reach levels that would activate relief valves. This beforehand cushioning prevents the need for relief valve activation and associated coolant discharge.
4Reliability
If the system achieves a 'permanently leak-tight' state with integrated pressure measurement, then explosion protection requirements are reduced and operating costs are saved, but manufacturing complexity increases
Solution Approach 1:
The pressure measurement equipment is designed to serve multiple functions: normal hydraulic system monitoring, leak detection, and continuous verification of leak-tightness. This multi-functionality achieves the permanently leak-tight state and reduced explosion protection requirements while avoiding the need for separate dedicated sensing systems, thereby managing manufacturing 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 approach achieves a 'permanently leak-tight' state, reduces explosion protection requirements, limits the development of harmful atmospheres, and integrates seamlessly into the hydraulic system without obstructing the filling process, resulting in cost savings and improved safety.
Implementation Method 1
Leak detection diagnosis can be performed in a simple manner using a pressure sensor that can be integrated in the system
Implementation Method 2
decoupling the clusters from one another using check valves
Implementation Method 3
one relief valve... Protection of hydraulic circuits from too high pressures
Implementation Method 4
small volumes having stop valves
Data Source
AI summary
The invention relates to a method for preventing and detecting coolant discharges from complex hydraulic systems. The aim of the invention is to configure such a method in such a way that this method in particular meets requirements for preventing/limiting the development of explosive atmospheres in working areas and for reducing measures from previously otherwise typical requirements for Ex zones. This aim is achieved in that a circuit carrying coolant is divided into small volumes that have stop valves and a relief valve, wherein a leak detection diagnosis can be carried out by means of a pressure sensor that can be integrated.