Hydraulic Unit Segmentation for Forklift Cylinder Control
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Solution Overview
Problem
Existing hydraulic systems for self-propelled forklift trucks face issues with complex control circuits leading to throttle losses and require a second supply pump for auxiliary functions, making them inefficient and prone to hose rupture.
Innovation Solution
A hydraulic system with a structurally separate control or regulating device and hydraulic unit, where the supply of hydraulic fluid to the cylinder is predominantly controlled from outside the unit, eliminating the need for internal control units and reducing throttle losses, and featuring a rigid fastening of the hydraulic unit to the cylinder for enhanced safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If control units are integrated in the hydraulic unit, then control function is achieved, but throttle losses increase and structure becomes complex
Solution Approach 1:
The system is divided into two separate assemblies: a hydraulic unit and a control/regulating device. The control unit is extracted from the hydraulic unit and placed in a separate structurally independent assembly, eliminating throttle losses while maintaining control functionality. The hydraulic unit contains only hydraulic components, while the control device handles all regulation functions externally.
Solution Approach 2:
The control and regulating device is extracted from the hydraulic unit and positioned in a separate assembly. This extraction eliminates the need for internal control units within the hydraulic assembly, thereby removing the source of throttle losses while preserving the control function through external fluidic connection.
2Adaptability or versatility
If hose connections are used between hydraulic components, then flexibility in installation is achieved, but reliability decreases due to hose rupture risk
Solution Approach 1:
The hydraulic unit and hydraulic cylinder are merged into a single rigidly fastened assembly, eliminating the need for hose connections at this critical interface. This merging provides both structural integrity and reliability while maintaining installation flexibility through the overall modular design of the separated assemblies.
3Ease of operation
If a single centralized control device is used, then control function is achieved, but installation space requirements increase
Solution Approach 1:
The system is segmented into a centralized control/regulating device and decentralized hydraulic units. The control device can be positioned centrally while hydraulic units are distributed at different locations, optimizing space utilization without compromising control functionality. Each hydraulic unit is compact and can be mounted in available spaces throughout the vehicle.
4Adaptability or versatility
If complex control circuits are used for auxiliary functions, then control capability is improved, but device complexity increases
Solution Approach 1:
The control and regulating device is extracted as a separate assembly with simplified internal structure. Complex control circuits for auxiliary functions are consolidated in this external device rather than being distributed within the hydraulic unit, reducing the complexity of the hydraulic assembly while maintaining full control capability.
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
The solution results in a simple, compact, and secure hydraulic system with reduced throttle losses, improved safety against hose rupture, and flexibility in installation, suitable for electric-drive vehicles, achieving high efficiency and energy savings.
Implementation Method 1
The hydraulic unit forms a second assembly. The first and second assembly are structurally separate from one another and fluidically connected. The supply of hydraulic fluid to the hydraulic cylinder can be predominantly controlled or regulated by the control or regulating device from outside the hydraulic unit.
Implementation Method 2
For the control or regulating function the two assemblies are fluidically connected to one another. This is accomplished, for example, by lines which interconnect the two structurally separate assembles.
Data Source
AI summary
The invention relates to a hydraulic system for controlling or regulating a hydraulic cylinder comprising—at least one hydraulic cylinder, at least one hydraulic unit by means of which the hydraulic cylinder can be optionally connected to a pressure source and a tank and at least one control or regulating device for controlling or regulating the supply of hydraulic fluid to the hydraulic cylinder, the control or regulating device forms a first assembly and the hydraulic unit forms a second assembly which are structurally separate from one another and fluidically connected, wherein the supply of hydraulic fluid to the hydraulic cylinder can be predominantly controlled or regulated by the control or regulating device from outside the hydraulic unit and wherein the hydraulic unit is rigidly fastened on the hydraulic cylinder.