Hydraulic Valve Layout for Decoupled Pressure and Flow Control
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Solution Overview
Problem
Existing hydraulic systems face challenges in productivity, flexibility, and energy efficiency, particularly in multi-circuit systems used in large machines like those in the mining sector, which are costly and space-intensive, and struggle to meet the demands of dynamic and precise control processes while adhering to strict energy and emissions regulations.
Innovation Solution
A valve device with separate, structurally distinct control edges that incorporate proportional valves, pressure control valves, and pressure compensators, allowing for decentralized control and efficient management of pressure and volume flow, enabling individual actuation of inflow and outflow and supporting various movement tasks, including floating and rapid traverse positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multi-circuit hydraulic systems are used to meet productivity and flexibility demands, then system performance and adaptability improve, but device complexity and cost increase
Solution Approach 1:
The patent implements a single-circuit hydraulic system where one hydraulic pump and one valve device serve multiple hydraulic consumers (hydraulic motor, hydraulic cylinder). The valve device can dynamically allocate hydraulic flow to different consumers based on their instantaneous requirements, enabling one system to perform multiple functions that would traditionally require separate circuits. This universal approach maintains system flexibility while eliminating the complexity of multiple independent circuits.
2Ease of operation
If traditional hydraulic systems with directional valves are used, then control functionality is achieved, but power loss and susceptibility to faults increase
Solution Approach 1:
The patent replaces traditional mechanical directional control valves with a valve device that uses a spool mechanism controlled by a control unit based on sensor feedback. This substitution eliminates the need for multiple mechanical spool valves and their associated shifting mechanisms, reducing mechanical complexity and energy losses associated with mechanical valve operation while maintaining full control functionality through a more efficient electro-hydraulic control approach.
3Measurement precision
If pressure regulators and throttles are used for control, then speed and position control are achieved, but response time increases and system complexity increases
Solution Approach 1:
The patent implements a closed-loop control system with sensors that continuously monitor the actual position and speed of hydraulic consumers and feed this information back to the control unit. The control unit processes this feedback and dynamically adjusts the valve spool position to maintain precise control. This feedback mechanism enables rapid response to changing conditions without the need for complex mechanical feedback linkages, achieving both precision and fast response time.
4Device complexity
If single-circuit hydraulic systems are used to reduce complexity, then device complexity and cost decrease, but control precision and adaptability worsen
Solution Approach 1:
The patent employs a dynamic control approach where the valve spool position is continuously and dynamically adjusted based on real-time sensor feedback from hydraulic consumers. The control unit processes feedback signals and modulates the hydraulic flow in real-time, enabling precise control of multiple consumers within a single circuit. This dynamic control mechanism maintains high precision despite the simplified single-circuit architecture, as the system adapts continuously to changing operational requirements.
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 valve device reduces energy consumption, minimizes power loss and susceptibility to faults, and enhances reaction time, contributing to cost savings and compliance with emissions regulations by optimizing energy use in hydraulic systems.
Implementation Method 1
a valve device with an inlet connection ZA on an inlet side for supplying a hydraulic consumer that can be connected to the inlet connection ZA with pressure fluid
Data Source
Figure 1~2
Figure 3a~3c
Figure 4a~4b
AI summary
A valve device having a feed connector (ZA) of a feed side for the supply of a hydraulic consumer which can be connected to the feed connector (ZA) with pressure fluid, an outlet connector (AA) of an outlet side for the discharge of pressure fluid from the consumer which can be connected, wherein, depending on the actuating direction of said consumer, the feed side changes into the outlet side and the outlet side changes into the feed side, a pressure supply connector (P), and a return flow connector (T), is characterized in that a pressure regulating device acts on the respective feed side and a volumetric flow regulating device acts on the respective outlet side.