Hydraulic Valve Diagnostics Using Pressure Test Signals
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Solution Overview
Problem
Hydraulic systems face challenges in monitoring the function of electrically operable valves without increasing complexity and cost, as existing displacement sensors are expensive and require complex signal processing, which can lead to malfunctions and potential damage.
Innovation Solution
A hydraulic system with a function diagnostics unit that uses hydraulic sensors and test sequences to monitor the operation of electrically operable valves by applying hydraulic test signals and comparing measurement signals with expected changes, eliminating the need for individual position sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If displacement sensors or position sensors are disposed on electrically operable valves to monitor valve positions, then valve malfunction detection is improved, but system cost and complexity increase
Solution Approach 1:
The hydraulic sensor serves multiple functions: it monitors pressure changes for valve malfunction detection, measures operational parameters for system control, and provides diagnostic information for maintenance. This single sensor replaces what would otherwise require multiple specialized sensors, reducing system complexity while maintaining comprehensive monitoring capability
Solution Approach 2:
The invention introduces a diagnostic unit that acts as an intermediary between the hydraulic sensor and the control system. This diagnostic unit processes sensor signals, compares them against expected values, and identifies valve malfunctions without requiring complex signal processing in the main control system, thereby simplifying overall system architecture
2Reliability
If displacement sensors or position sensors are disposed on electrically operable valves to monitor valve positions, then valve malfunction detection is improved, but system cost increases
Solution Approach 1:
The invention employs standard hydraulic pressure sensors that are relatively inexpensive and widely available, replacing expensive displacement or position sensors. These conventional sensors are used in a novel diagnostic application, achieving reliable valve monitoring at lower cost through creative reuse of affordable components
Solution Approach 2:
By using a single hydraulic sensor for multiple monitoring purposes rather than installing specialized sensors on each valve, the system achieves comprehensive valve surveillance with minimal hardware investment, significantly reducing overall system cost while maintaining high reliability
3Reliability
If a large number of sensors are used to monitor hydraulic system components, then monitoring reliability is improved, but signal transmission and processing complexity increases
Solution Approach 1:
The diagnostic unit serves as an intelligent intermediary that receives signals from the hydraulic sensor, performs local analysis by comparing measured pressure changes against expected operational ranges, and generates diagnostic outputs. This distributed intelligence approach eliminates the need for complex centralized signal processing, reducing communication bandwidth requirements and simplifying the control system architecture
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 system provides reliable and cost-effective monitoring of valve functions, ensuring precise control and preventing damage by detecting defects in electrically operable valves through simple and efficient diagnostic methods.
Implementation Method 1
a first hydraulic sensor (16) is disposed in the first line arrangement (12) downstream of the first electrically operable valve (20) as seen from the pressure line (P) and upstream of the second electrically operable valve (22) as seen from the hydraulic consumer (V)
Data Source
AI summary
A hydraulic system includes a hydraulic consumer and a first line arrangement. The first line arrangement connects the hydraulic consumer to a pressure line via a first electrically operable valve and to a tank line via a second electrically operable valve. A first hydraulic sensor is disposed in the first line arrangement downstream of the first electrically operable valve, seen from the pressure line, and upstream of the second electrically operable valve, seen from the hydraulic consumer. The hydraulic system further includes a function diagnostics unit for carrying out a first test sequence and a second test sequence. In the first test sequence, a first hydraulic test signal is applied by activating the first electrically operable valve for a first time interval. The function diagnostics unit is configured to record a measurement signal from the first hydraulic sensor and to compare the measurement signal with the first hydraulic test signal.