Hydraulic Valve Failure Detection via Pressure Monitoring
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Solution Overview
Problem
In electro-hydrostatic actuator systems, the failure of a load-holding valve to close fully can lead to persistent pressure, indicating leakage, which complicates controlled lowering of loads and requires operator warnings, as existing systems lack effective detection and response mechanisms.
Innovation Solution
A controller-connected hydraulic system with a load-holding valve and a backup control routine that monitors system conditions, evaluates valve closure, and initiates actions such as depressurizing the hydraulic fluid or alerting the operator, ensuring safe and controlled load lowering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the load-holding valve is used to hold the load, then the load can be maintained in position, but the valve may fail to close fully causing persistent pressure and potential safety issues
Solution Approach 1:
The system continuously monitors the pressure differential across the load-holding valve using pressure sensors. When the valve fails to close properly, the feedback mechanism detects the abnormal pressure persistence and triggers an alert to the operator, enabling timely intervention to prevent safety hazards.
Solution Approach 2:
A pressure differential sensor acts as an intermediary between the load-holding valve and the control system. This sensor detects the valve's closure status by measuring pressure differences and transmits this information to the controller, which then generates appropriate warnings or control signals.
2Productivity
If traditional hydraulic systems are replaced with electro-hydrostatic actuator systems, then energy efficiency and control precision are improved, but the complexity of detecting and responding to valve failures increases
Solution Approach 1:
The electro-hydrostatic actuator system performs self-diagnosis by continuously monitoring its own operational parameters. The control system automatically detects valve failure conditions through sensor data and can initiate backup control routines without external intervention, reducing the need for complex external monitoring systems.
Solution Approach 2:
The control system is designed to perform multiple functions: normal actuator control, valve failure detection, backup control routine initiation, and operator alerting. This multi-functionality consolidates what could be separate complex systems into a single integrated control unit.
3Stability of the object's composition
If the pump continues to supply pressure when the valve fails to close, then the actuator can maintain position, but the persistent load torque indicates valve failure and potential system damage
Solution Approach 1:
The system takes preliminary action by detecting the valve failure condition through persistent load torque or pressure differential monitoring before actual system damage occurs. The control system then initiates corrective actions such as alerting the operator or activating backup control routines to prevent further damage.
Solution Approach 2:
The control system continuously monitors system parameters and is prepared to initiate backup control routines in advance when valve failure is detected. This preliminary response ensures that the actuator can be safely controlled even after valve failure, maintaining system reliability.
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
Enables safe and controlled lowering of loads by detecting valve failure and initiating backup control routines, reducing the risk of accidents and providing timely warnings to operators.
Implementation Method 1
a pump operable in a first direction for supplying pressurized fluid
Implementation Method 2
The load-holding valve may be controlled by the controller and operative in a first position to allow flow to the actuator to operate the actuator against a load and operative in a second position to block load-induced return flow from the actuator to the pump
Implementation Method 3
The controller may be configured to receive a requested actuator stop, to control the first valve to move to the second position in response to the requested actuator stop, to monitor a first system condition in response to the requested actuator stop
Data Source
AI summary
According to one aspect of the invention, a hydraulic system includes a controller connected to an operator interface, a pump operable in a first direction for supplying pressurized fluid, and a load-holding valve connected between the pump and a port for connection to an actuator. The load-holding valve may be controlled by the controller and operative in a first position to allow flow to the actuator to operate the actuator against a load and operative in a second position to block load-induced return flow from the actuator to the pump. The controller may be configured to receive a requested actuator stop, to control the first valve to move to the second position in response to the requested actuator stop, to monitor a first system condition in response to the requested actuator stop, to evaluate the monitored system condition with a prescribed criteria, and to determine whether or not to initiate a back-up control routine based on the evaluation.