Hydrostatic Machine Wear Assessment Using Torque and Leakage Data
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for determining the state of wear in hydrostatic machines are unable to accurately account for leakage in hydraulic systems, leading to inaccuracies in wear assessment and maintenance planning.
Innovation Solution
A method involving the determination of drive torque and volume flow, using calculation methods such as multivariate regression, lookup tables, physical models, and machine learning, to assess the state of wear by comparing actual and calculated torques, accounting for system variables like viscosity, temperature, and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If volume flow measurement is used to determine wear state, then wear assessment can be performed, but leakage in hydraulic system cannot be distinguished from pump wear
Solution Approach 1:
The hydraulic system is segmented into multiple measurement zones: pump inlet, pump outlet, and hydraulic component outlets. By measuring volume flow at multiple locations and comparing the differences, the system can identify whether leakage occurs in the pump or in downstream components, thereby localizing the wear cause.
Solution Approach 2:
The patent introduces pressure measurements as an intermediary parameter to distinguish between pump wear and hydraulic system leakage. By combining pressure data with volume flow measurements, the system can calculate power consumption and identify the specific source of efficiency loss.
2Ease of operation
If wear measurement is performed during operation, then maintenance can be optimized, but accurate wear determination requires defined operating conditions
Solution Approach 1:
The system dynamically adapts to varying operating conditions by continuously measuring multiple parameters (pressure, volume flow, power) and using these real-time data to assess wear state. The method does not require the system to be operated at predefined points, allowing wear assessment under actual operating conditions.
Solution Approach 2:
The patent utilizes changes in multiple parameters (pressure, volume flow, power consumption) to assess wear state. By monitoring how these parameters change during operation and comparing them to reference values from a healthy system, the method can determine wear without requiring fixed operating conditions.
3Measurement precision
If torque and volume flow are measured to assess wear, then wear state can be determined, but the method requires multiple sensors and calculations
Solution Approach 1:
The system uses a multi-functional measurement approach where the same sensors (pressure sensors, flow sensors) serve multiple purposes: measuring operating conditions, calculating power consumption, and assessing wear state. This reduces the need for additional specialized sensors while maintaining comprehensive monitoring capability.
Data Source
AI summary
The present invention relates to a method for determining a present state of wear of a hydrostatic machine during the operation of the hydrostatic machine. The hydrostatic machine comprises a drive with variable rotational speed and a hydrostatic pump, wherein the drive is designed to drive the hydrostatic pump for generating a volume flow of a fluid, and wherein the hydrostatic machine is connected to a fluid transport channel in which the fluid is transported in a manner driven by the hydrostatic machine. The method has a step for determining a first torque of the drive at a specified drive vector. Furthermore, the method has a step for ascertaining a second torque of the drive at the specified drive vector using a first calculation method, and in addition, the method has a step for determining the present state of wear of the hydrostatic machine using a second calculation method, in order to compare the first determined torque and the second ascertained torque to one another.