Implement-Position Hydraulic Pressure Control for Payload Durability
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Solution Overview
Problem
In mining work machines, the forced commonality of hydraulic systems due to size constraints leads to overloading and premature wear of components, as larger hydraulic cylinders are often used with smaller machines, resulting in performance degradation or structural mass increases.
Innovation Solution
A hydraulic system with a controller that adjusts between multiple system pressures based on the implement's position, using a combination of a shared hydraulic reservoir, pump, and pressure relief system, including load sense and pressure relief valves, to optimize pressure distribution and prevent overloading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If larger hydraulic cylinders are placed on machines designed for smaller hydraulic cylinders to meet size constraints, then the machine can handle higher payloads, but components become overloaded causing failure or premature failure
Solution Approach 1:
The patent implements a dynamic pressure control system that adjusts hydraulic system pressure based on implement position. The controller monitors position sensors and dynamically modifies pump output pressure, allowing the system to provide high pressure only when needed for lifting payloads, while maintaining lower pressure during positioning operations. This resolves the contradiction by enabling high payload capacity without continuously overloading components.
Solution Approach 2:
The system changes the pressure parameter dynamically based on operational conditions. By using position sensors to detect implement location and a controller to adjust pump pressure accordingly, the system adapts pressure levels to match actual workload requirements. This allows the same hydraulic components to handle both high payload scenarios and normal operation without premature failure.
2Power
If the machine is designed to withstand the loads of larger hydraulic cylinders or higher pressures, then higher payloads can be handled, but mass increases for the structure which can decrease the performance of the machine
Solution Approach 1:
The dynamic pressure control system allows the hydraulic components to be sized for moderate capacity rather than maximum capacity. Since pressure is only elevated when needed for actual lifting, the structural components can be optimized for normal operating conditions rather than peak extremes, reducing overall machine mass while maintaining payload capability.
Solution Approach 2:
By changing pressure parameters dynamically rather than maintaining constantly high pressure, the system enables use of lighter structural components. The components are designed for the average operational pressure rather than peak pressure, reducing mass while still handling maximum payloads when required through temporary pressure elevation.
3Power
If higher hydraulic pressure is maintained continuously to enable higher payloads, then power is available for lifting, but components wear out prematurely due to lack of restrictions on use
Solution Approach 1:
The system dynamically adjusts pressure based on actual lifting needs rather than maintaining constant high pressure. Position sensors detect when the implement is in a lifting position, and the controller elevates pressure only during these specific moments. During positioning, transport, and other non-lifting operations, pressure remains low, dramatically reducing cumulative wear on seals, hoses, and components while maintaining full power availability when needed.
Solution Approach 2:
High pressure is applied periodically only when lifting operations are detected, rather than continuously. The controller monitors position sensors and activates high pressure in periodic cycles corresponding to actual lifting tasks. This intermittent high-pressure operation significantly extends component service life while maintaining the capability to handle high payloads when required.
Data Source
AI summary
A hydraulic system for controlling an implement on a work machine may include a hydraulic reservoir, a hydraulic pump in fluid communication with the reservoir, a central valve in fluid communication with the pump and configured for controlling the implement, a pressure relief system arranged in fluid communication with the hydraulic pump and the central valve, and a controller. The controller may be configured for controlling the hydraulic pump, the central valve and the pressure relief system and selecting between operating the hydraulic system at a first pressure and a second pressure based on a factor relating to implement position.