Hydraulic Machine Valve Control for Multi-Actuator Energy Allocation
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Solution Overview
Problem
Industrial vehicles with multiple hydraulically powered actuators face inefficiencies in energy usage, leading to increased fuel consumption and operational costs, as existing hydraulic control systems struggle to optimize energy distribution and prevent engine droop and stalling.
Innovation Solution
The implementation of an electronically commutated hydraulic machine with a rotatable shaft and working chambers, featuring low-pressure and high-pressure valves, which actively control fluid displacement in response to demand signals, and a controller that calculates and regulates the displacement of working chambers to optimize energy use and prevent engine droop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional hydraulic control systems are used to supply multiple actuators, then the system can operate all actuators, but energy efficiency deteriorates and fuel consumption increases
Solution Approach 1:
The patent implements dynamic allocation of working chambers to actuators based on real-time demand signals. The controller continuously monitors actuator requirements and reconfigures which working chambers supply which actuators, optimizing energy distribution dynamically rather than using fixed connections. This dynamic reconfiguration ensures that hydraulic power is directed only to actuators that need it, improving overall energy efficiency.
Solution Approach 2:
The system changes the operational parameters of working chambers by actively controlling valve timing to select the net displacement of hydraulic fluid on each cycle. By adjusting valve timing and displacement parameters in response to demand signals, the system optimizes energy transfer efficiency to match actual actuator needs, reducing energy waste.
2Use of energy by moving object
If hydraulic machine actively controls valve timing to optimize energy distribution, then energy efficiency improves, but device complexity increases
Solution Approach 1:
The controller serves multiple functions: it monitors demand signals from actuators, determines optimal allocation of working chambers, controls valve timing for multiple working chambers, and prevents engine droop. By consolidating these control functions into a single multi-functional controller, the patent manages complexity while achieving energy optimization.
Solution Approach 2:
The system uses feedback from demand signals to continuously adjust working chamber allocation and valve timing. The controller receives information about actuator requirements and uses this feedback to optimize energy distribution in real-time, creating a closed-loop control system that adapts to changing conditions without requiring overly complex predetermined control logic.
3Loss of energy
If working chambers are dynamically allocated to actuators, then fuel consumption reduces, but system reliability may deteriorate due to increased control complexity
Solution Approach 1:
The controller proactively manages working chamber allocation and valve timing based on anticipated and actual actuator demands. By preparing and adjusting the hydraulic power distribution in advance and in real-time, the system ensures smooth transitions and prevents conditions that could lead to engine droop or stalling, thereby maintaining reliability while optimizing fuel consumption.
Solution Approach 2:
The closed-loop feedback system continuously monitors actuator demand and system operation, allowing the controller to detect and correct potential issues before they compromise reliability. This real-time feedback ensures that dynamic allocation does not compromise system stability or cause engine droop, maintaining reliable operation while reducing fuel consumption.
4Use of energy by moving object
If valve timing is actively controlled to regulate fluid displacement, then energy distribution optimizes, but ease of operation deteriorates
Solution Approach 1:
The system performs self-service through automated controller management of working chamber allocation and valve timing. The controller independently monitors actuator demands and adjusts hydraulic power distribution without requiring manual intervention or complex operator decisions. This automation simplifies operation for the user while achieving optimized energy distribution through sophisticated internal control.
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 solution enhances energy efficiency, reduces fuel consumption, and prevents engine stalling by dynamically allocating working chambers to actuators and regulating fluid flow, thereby improving the overall performance of industrial vehicles.
Implementation Method 1
a hydraulic machine having a rotatable shaft in driven engagement with the prime mover and comprising a plurality of working chambers having a volume which varies cyclically with rotation of the rotatable shaft (e.g. each chamber is defined by a cylinder within which a piston reciprocates in use)
Implementation Method 2
each working chamber of the hydraulic machine comprising a low-pressure valve which regulates the flow of hydraulic fluid between the working chamber and a low-pressure manifold
Implementation Method 3
a high-pressure valve which regulates the flow of hydraulic fluid between the working chamber and a high-pressure manifold
Data Source
AI summary
A prime mover and hydraulic actuators, a hydraulic machine having a rotatable shaft engaged with the prime mover and having a plurality of working chambers, a hydraulic circuit extending between a group of working chambers of the hydraulic machine and the hydraulic actuators, each working chamber of the hydraulic machine having a low-pressure and a high-pressure valve regulating the flow of hydraulic fluid between the working chamber and a corresponding low-pressure manifold and a high-pressure manifold. The hydraulic machine controlling the low-pressure valves of the group of working chambers to select the net displacement of hydraulic fluid by each working chamber on each cycle of working chamber volume, and thereby the net displacement of hydraulic fluid by the group of working chambers, responsive to a demand signal, the apparatus further having a controller calculating the demand signal responsive to a measured property of the hydraulic circuit or an actuator.