Hydraulic Tool Controller for Dynamic Engine Speed Adjustment
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Solution Overview
Problem
Hydraulic systems face inefficiencies due to large, noisy engines being overpowered for certain tasks, leading to fuel inefficiency and reduced tool life, with manual adjustments being inaccurate and labor-intensive, especially when multiple tools are used simultaneously.
Innovation Solution
A system with a hydraulic supply and a controller that adjusts the speed of a drive coupled to a hydraulic pump based on feedback from hydraulic loads, allowing for electronic and automatic adjustment of hydraulic output to match the demand of multiple tools, enabling simultaneous use and optimizing engine power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large engine is used to power hydraulic pumps, then sufficient power is available for hydraulic tools, but the engine becomes noisy and fuel inefficient
Solution Approach 1:
The patent implements dynamic engine speed control that adjusts the engine operating speed based on the actual hydraulic load demand. The controller continuously monitors hydraulic system requirements and modulates engine speed accordingly, transitioning from static full-power operation to dynamic adaptive operation. This resolves the contradiction by providing sufficient power when needed while reducing fuel consumption during lower-demand operations.
Solution Approach 2:
The system changes the operational parameters of the engine by adjusting speed based on hydraulic load conditions. The controller modifies engine speed as a variable parameter rather than maintaining constant operation, allowing the system to adapt power output to match actual tool requirements. This parameter adjustment resolves the contradiction between maintaining high power capability and improving fuel efficiency.
2Ease of operation
If manual adjustments are made to hydraulic system output, then power can be matched to tool needs, but the process becomes labor-intensive and inaccurate
Solution Approach 1:
The patent implements a feedback control system where the controller continuously monitors hydraulic load conditions and automatically adjusts engine speed and pump output accordingly. Sensors detect actual tool requirements and feed this information back to the controller, which then modulates hydraulic output in real-time. This eliminates manual adjustment operations and provides accurate, rapid response to changing tool demands, resolving both the ease of operation and time loss issues.
Solution Approach 2:
The hydraulic system performs self-adjustment through the automated control system that monitors and regulates its own output based on tool requirements. The controller automatically manages engine speed and hydraulic flow without requiring operator intervention, allowing the system to serve itself in matching power delivery to actual needs. This resolves the contradiction by eliminating labor-intensive manual adjustments while maintaining accurate power matching.
3Power
If full hydraulic output is provided at full engine speed, then maximum power is available to tools, but this causes over-use and reduces tool life
Solution Approach 1:
The patent implements partial action by providing only the necessary hydraulic power required by the tools rather than continuous full-power output. The controller modulates engine speed and pump flow to deliver appropriate power levels matched to actual tool demands, avoiding excessive power application. This resolves the contradiction by providing sufficient power for tool operation while preventing over-use that would reduce tool life.
4Productivity
If multiple hydraulic tools are used simultaneously, then productivity increases, but manual adjustment becomes more difficult and inaccurate
Solution Approach 1:
The control system uses feedback from multiple tool circuits to automatically balance and distribute hydraulic power among simultaneously operating tools. The controller monitors pressure and flow conditions in each tool circuit and adjusts pump output and engine speed to maintain optimal power distribution. This resolves the contradiction by enabling simultaneous multi-tool operation with accurate power distribution that would be impossible to achieve through manual adjustment.
Solution Approach 2:
The automated control system provides universal power management capability that handles multiple tool configurations and operating conditions through a single integrated system. The controller can manage various tool combinations simultaneously, automatically adapting power distribution to meet the collective demands of all active tools. This multi-functional capability resolves the contradiction by providing precise power distribution across multiple tools without the complexity and inaccuracy of manual adjustment.
Data Source
AI summary
The present disclosure provides embodiments directed towards a system for the control of hydraulic output by a hydraulic power source. In one embodiment, a system is provided. The system includes a hydraulic supply system having a drive, a hydraulic pump coupled to the drive, a first hydraulic output configured to supply a first flow of a hydraulic fluid from the hydraulic pump to a hydraulic lift, a second hydraulic output configured to supply a second flow of the hydraulic fluid from the hydraulic pump to a first hydraulic tool, and a controller configured to adjust a speed of the drive in response to a feedback indicative of a first load by the hydraulic lift, a second load by the first hydraulic tool, or a combination thereof.