Hydraulic Warmup Valve Control for Cold Startup
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Solution Overview
Problem
Hydraulic machines experience unpredictable and sluggish operation, and potential damage due to cold temperatures, as existing warmup procedures may not adequately warm valves, leading to sticking or damage.
Innovation Solution
A machine control system with a pump, low-pressure reservoir, bypass passage, warmup valve, hydraulic temperature sensor, and pressure sensor, controlled by a controller to selectively direct pressurized fluid and adjust pump outlet pressure to warm the system efficiently, ensuring valves are warmed properly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the machine operates in cold temperatures, then the machine can be used immediately, but the hydraulic fluid and valves remain too cold causing unpredictable operation and potential damage
Solution Approach 1:
The system performs a warmup procedure before normal operation by circulating hydraulic fluid through a warmup circuit that bypasses the actuators. This preliminary action warms the hydraulic fluid and valves to appropriate temperatures, ensuring reliable operation before the machine is fully operational.
Solution Approach 2:
A warmup valve is introduced as an intermediary component that directs hydraulic fluid through a warmup circuit containing a flow restrictor. This intermediary circuit allows controlled circulation of fluid to warm components without requiring full system operation, mediating between cold startup and normal operation.
2Temperature
If the warmup procedure circulates fluid through all components, then the hydraulic fluid warms up, but the valves may overheat or stick due to excessive heating rate
Solution Approach 1:
The system changes the flow parameters of hydraulic fluid during warmup by using a flow restrictor in the warmup circuit. This restrictor limits the flow rate and pressure to specific values that provide gentle, controlled heating, preventing valves from overheating while still warming the hydraulic fluid to operational temperature.
Solution Approach 2:
The warmup circuit provides different flow conditions for different parts of the hydraulic system. By directing fluid through a restricted path that bypasses actuators but passes through valves and hoses, the system applies localized gentle heating to components that need warming while avoiding excessive heat generation.
3Temperature
If the pump operates at high pressure during warmup, then the warmup is effective, but oil leakage increases and energy is wasted
Solution Approach 1:
The system changes pressure parameters during warmup operation by using a flow restrictor that maintains lower pressure levels compared to normal operation. This reduced pressure during warmup minimizes oil leakage through seals and joints while still providing sufficient heat to warm hydraulic components, reducing energy waste.
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 effectively warms hydraulic machines, minimizing damage and ensuring smooth operation by controlling fluid temperature and pressure, thereby reducing oil leakage and preparing the machine for operation quickly.
Implementation Method 1
A pump is driven to pressurize fluid
Implementation Method 2
the microcomputer increases a rotational speed of the engine to a predetermined rotational speed, and then slowly adjusts a discharge oil amount and a pressure of the hydraulic pump and the valve until a load on the engine reaches a predetermined amount
Data Source
AI summary
A control system for a machine is disclosed. The control system may have a bypass passage situated to allow fluid to bypass an actuator, and a warmup valve disposed within the bypass passage that is movable between flow-passing and-blocking positions. A controller is configured to move the warmup valve to the flow-passing position, fix a displacement position of the pump, compare the pressure of the fluid of the actuator with a threshold, and move the warmup valve to the flow-blocking position and reduce a pump outlet pressure when the pressure of the fluid is greater than the threshold. The controller may be configured to move the warmup valve to the flow-passing position, fix a displacement position of the pump, and adjust an input speed of the pump in response to the signal.