Hydraulic Control Valve Feedback for Incorrect Valve Settings
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Solution Overview
Problem
Hydraulic consumers, such as agricultural implements, often experience undesired hydraulic power losses due to incorrect settings of control valves, leading to excessive system pressure and delivery volume flow mismatches, particularly in hydraulic rotary drives and linear controllers.
Innovation Solution
A method that utilizes sensor-acquired information to detect incorrect settings in electrically actuated control valves, adjusting valve positions or pressure threshold values to match the requirements of hydraulic consumers, thereby preventing power losses. This involves sending system pressure and pivot angle data to a control unit, which outputs operator information and initiates countermeasures like adjusting valve positions or reducing pressure thresholds based on detected issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the control valve is moved to a completely open valve position, then the axial piston pump is pivoted to full output, but the delivery volume flow becomes too high and requires throttling
Solution Approach 1:
The control unit receives sensor-acquired information about the current system pressure and current pivot angle, compares the actual delivery volume flow with the expected value based on valve position, and automatically adjusts the valve position to match the hydraulic consumer's actual demand, eliminating the need for throttling and reducing hydraulic power losses
Solution Approach 2:
The system dynamically changes the valve position parameter based on real-time feedback from sensors, adjusting the delivery volume flow to match the actual hydraulic consumer demand rather than maintaining a fixed fully-open position, thereby optimizing energy efficiency
2Stress or pressure
If the control valve is moved to a completely open valve position, then the system pressure assumes a maximum value, but this causes unnecessary hydraulic power losses in hydraulic linear controllers
Solution Approach 1:
The control unit monitors the system pressure via sensors and compares it with the expected pressure based on the connected hydraulic consumer's requirements. When a mismatch is detected (maximum pressure without corresponding delivery volume flow), the control unit automatically adjusts the valve position to reduce pressure to the appropriate level, eliminating unnecessary hydraulic power losses
Solution Approach 2:
The system uses its own sensor-acquired information about system pressure and pivot angle to automatically detect and correct incorrect settings, enabling the hydraulic system to self-regulate and optimize its operating parameters without external intervention
3Reliability
If sensor-acquired information is sent to a control unit for detection, then incorrect settings can be reliably detected, but the device complexity increases
Solution Approach 1:
The control unit performs multiple functions: it receives sensor data about system pressure and pivot angle, compares actual delivery volume flow with expected values, detects incorrect settings, and automatically adjusts valve positions. This multi-functionality consolidates what would otherwise require separate components into a single integrated control system
Solution Approach 2:
The control unit uses the system's own sensor-acquired information to automatically detect and correct incorrect settings, eliminating the need for separate detection and correction systems. The system monitors and adjusts itself, reducing overall complexity while maintaining high detection reliability
Data Source
AI summary
A method for operating a hydraulic consumer on an electrically actuated control valve includes providing the valve with an open valve position for establishing a connection between a valve inlet and a pilot line for influencing a pivot angle set on an axial piston pump and a system pressure which is present at the valve inlet and dependent on the pivot angle. Data regarding the current system pressure and the current pivot angle are detected and communicated to a control unit. The method includes determining an incorrect setting of the control valve if the control unit detects that a delivery volume flow of the axial piston pump is smaller than a value to be expected based on valve position, or the control unit detects that the system pressure present at the valve inlet is at a maximum without a delivery volume flow flowing in the direction of the hydraulic consumer.