Hydraulic Valve Controller with Non-Linear Flow Mapping
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Solution Overview
Problem
Operators of hydraulic valves in work vehicles face challenges in precisely controlling low flow rates while allowing rapid operation, due to the linear relationship between control lever movement and flow rate, which is insufficient for nuanced control around the central position.
Innovation Solution
A controller that allows non-linear assignment of hydraulic valve flow rates to different ranges of control device movement, enabling precise control at central positions and rapid operation at outer positions by creating a non-linear relationship between valve flow rates and joystick movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a linear relationship between control lever movement and flow rate is used, then the system is simple to operate, but precise control of low flow rates around the central position is difficult
Solution Approach 1:
The patent applies dynamics by making the flow rate characteristic adjustable and variable. The controller can switch between different flow rate characteristics (linear, non-linear, customized curves) based on operational requirements. This allows the system to adapt its control characteristics dynamically - using non-linear characteristics when precise low flow rate control is needed and linear characteristics when simple operation is prioritized.
Solution Approach 2:
The patent changes the parameter of flow rate characteristic from fixed linear to variable (non-linear or customized). By modifying the relationship between control lever position and flow rate output, the system achieves better precision for low flow rates while maintaining operational simplicity through selectable characteristics. The controller stores multiple characteristic curves and can switch between them based on the implement type or operational mode.
2Measurement precision
If a non-linear relationship between control lever movement and flow rate is used, then precise control of low flow rates is improved, but the system complexity increases
Solution Approach 1:
The patent replaces complex mechanical flow control mechanisms with an electronic control system. Instead of using complex mechanical valve arrangements to achieve non-linear flow characteristics, the system uses a controller that processes electronic signals from the control lever and generates appropriate control signals for the hydraulic valve. This substitution reduces mechanical complexity while achieving the desired non-linear flow rate characteristics through software algorithms and lookup tables.
Solution Approach 2:
The controller serves multiple functions: it reads control lever position, determines desired flow rate based on non-linear characteristics, compensates for system variations, and outputs control signals to the hydraulic valve. By consolidating these functions in a single electronic controller, the system achieves precise non-linear flow control without proportionally increasing overall system complexity.
3Ease of manufacture
If the same maximum flow rate is provided in both extend and retract modes, then the valve is symmetric and simple to manufacture, but it cannot provide optimized flow rates for different operational directions
Solution Approach 1:
The patent applies dynamics by making the flow rate characteristic adjustable and variable. The controller can switch between different flow rate characteristics (linear, non-linear, customized curves) based on operational requirements. This allows the system to adapt its control characteristics dynamically - using non-linear characteristics when precise low flow rate control is needed and linear characteristics when simple operation is prioritized.
Solution Approach 2:
The patent changes the parameter of flow rate characteristic from fixed linear to variable (non-linear or customized). By modifying the relationship between control lever position and flow rate output, the system achieves better precision for low flow rates while maintaining operational simplicity through selectable characteristics. The controller stores multiple characteristic curves and can switch between them based on the implement type or operational mode.
Data Source
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AI summary
An arrangement for controlling the flow rate through a hydraulic valve, the arrangement comprising a control device having a first range of positions for providing a first range of flow rates through the hydraulic valve, a second range of positions for providing a second range of flow rates through the hydraulic valve, and a neutral position for providing substantially no flow through the hydraulic valve, wherein the relationship between the first range of flow rates through the hydraulic valve and the first range of positions of the control device is substantially linear having a first ratio and the relationship between the second range of flow rates through the hydraulic valve and the second range of positions of the control device is substantially linear having a second ratio.