Hydraulic System Warm-Up via Differential Pressure Control
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Solution Overview
Problem
Existing hydraulic systems for working machines lack an efficient method for warming up the fluid circuits, leading to potential operational inefficiencies and increased wear due to cold starts.
Innovation Solution
The hydraulic system incorporates a network of fluid tubes and valves that allow for differential pressure control between the brake and speed-changing mechanisms, enabling the warm-up of fluid circuits by directing operation fluid flow through specific paths during the warm-up mode, ensuring efficient heating of critical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the hydraulic system uses a single fluid tube for both brake and speed-changing mechanisms, then the device complexity is reduced, but the ability to perform differential pressure control for warm-up is lost
Solution Approach 1:
The hydraulic system divides the fluid circulation path into separate first and second fluid tubes: the first fluid tube connects the brake mechanism and brake operation valve, while the second fluid tube connects the speed-changing mechanism and speed-changing operation valve. This segmentation enables independent pressure control for each mechanism, allowing the system to perform differential pressure control during warm-up mode without increasing overall system complexity.
2Reliability
If the brake set pressure is higher than the speed-changing set pressure, then the brake mechanism can maintain proper pressure during warm-up, but the speed-changing mechanism cannot utilize the pressure differential for effective warm-up
Solution Approach 1:
The system dynamically adjusts the set pressures of the brake operation valve and speed-changing operation valve based on operational mode. During normal operation, the brake set pressure is maintained higher than the speed-changing set pressure for reliable braking. During warm-up mode, the controller reverses this relationship by setting the speed-changing set pressure higher than the brake set pressure, enabling effective pressure differential-driven fluid circulation for warming the hydraulic fluid.
Solution Approach 2:
The controller changes the pressure parameters of the operation valves based on the operational mode. When warm-up mode is detected, the controller adjusts the speed-changing operation valve to provide a higher set pressure than the brake operation valve, creating a pressure differential that drives fluid circulation through the heat exchangers. This parameter change enables the system to switch between reliable braking operation and efficient warm-up operation.
3Device complexity
If the hydraulic system lacks a dedicated warm-up mode with differential pressure control, then the device complexity is reduced, but the operational efficiency and component lifespan are decreased due to cold starts
Solution Approach 1:
The existing brake and speed-changing hydraulic circuits are made multi-functional by enabling them to serve both their primary functions (braking and speed control) and a secondary warm-up function. The controller achieves this by reversibly adjusting the set pressures of the operation valves based on operational mode, allowing the same hardware to perform both operational control and thermal management without adding dedicated warm-up components.
4Productivity
If the system uses reversible pressure differential control between brake and speed-changing valves, then the warm-up effectiveness is improved, but the control system complexity increases
Solution Approach 1:
The hydraulic system performs self-warm-up by utilizing its own operational components (brake and speed-changing valves and fluid tubes) to generate the necessary pressure differentials for fluid circulation. The controller simply reverses the normal pressure relationship between the two valves, and the system's existing hydraulic architecture automatically facilitates the warm-up process without requiring external heating devices or complex additional control mechanisms.
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 allows for effective warming of the hydraulic fluid circuits, reducing operational inefficiencies and wear, while improving the overall performance and reliability of the working machine by ensuring that all components are properly heated before operation.
Implementation Method 1
The pilot fluid flowing into the heat-up fluid tube is supplied to the operation fluid tank through the relief valve or the throttle, thereby heating up the valve body
Data Source
AI summary
A hydraulic device includes a braking device to brake a traveling device and release braking of the traveling device, a traveling pump to drive the traveling device with pressure of operation fluid, a brake-operation valve to control operation fluid flowing to the brake device, a traveling operation valve to control operation fluid flowing to the traveling pump, a first discharge fluid tube to discharge operation fluid flowing through the brake-operation valve, the first discharge fluid tube being connected to the brake operation valve, and a second discharge fluid tube to discharge operation fluid flowing through the traveling operation valve, the second discharge fluid tube being connected to the traveling operation valve. The traveling operation valve has a set pressure that is set to be higher than a brake set pressure set by the brake operation valve.