Hydraulic Fluid Warmup System Using Controlled Pressurization
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Solution Overview
Problem
Dual pump hydraulic systems and single function systems face challenges in rapidly warming hydraulic fluid due to the inability to simultaneously stall over relief and actuate, leading to inefficient heating in cold environments.
Innovation Solution
A system and method that utilize a microcontroller to manage controlled pressurization and release of hydraulic pressures, forcing pumps to operate at full pressure and actuate implements to rapidly warm the fluid, with rate limiting to prevent aggressive behavior and optimize power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a dual pump system is used to provide hydraulic flow to implement functions, then each pump can independently control a function, but the system cannot rapidly warm hydraulic fluid because stalling one function with another actuating does not generate sufficient heat
Solution Approach 1:
The system dynamically switches between normal operational mode and warmup mode. During warmup, the controller actively manages pump operations to generate heat by creating controlled pressure conditions that differ from normal operation, allowing the system to adapt its behavior based on temperature requirements
Solution Approach 2:
The system changes operational parameters by forcing pumps to operate at full pressure and controlling implement actuation during warmup mode. This creates high-pressure, high-flow conditions that generate sufficient heat to rapidly warm the hydraulic fluid, contrasting with normal operational parameters
2Device complexity
If a single load sensing pump is used to provide hydraulic flow to all implement functions, then the system structure is simplified, but stalling one function causes the pump to move fluid at relief pressure consuming power and heating the fluid, which is inefficient
Solution Approach 1:
The controller monitors system conditions and provides feedback to manage pump operations. During warmup, the controller detects when functions are stalled and actively manages the single pump to create controlled pressure conditions that generate heat without excessive power consumption, using feedback from system state sensors
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 solution effectively accelerates hydraulic system warming to optimal operating temperatures, improving performance and reducing power consumption by maintaining full pressure and flow until the fluid reaches the desired temperature.
Implementation Method 1
a pump controller to increase fluid pressure
Implementation Method 2
the pressure of the fluid acts on hydraulic surfaces of the chambers to affect movement of the actuator
Data Source
AI summary
In accordance with an example embodiment, a system for managing a unique hydraulic system warmup method is described. A warmup system controller is central to the system and provides an interfacing point for communication to hardware components and a machine operator. The warmup system issues commands based on sensor inputs in light of defined rules and/or known physical properties of hydraulic fluids. Hydraulic system warmup is managed by the warmup system controller, which is configured to issue commands to affect hydraulic pumps and valves. By way of a controller managed process, the system functions to maximize hydraulic system pressure and limiting release of pressures in the lines, such that the pumps are able to maintain maximum pressure for a sufficient period of time.