Integrated Hydraulic Power Unit for Compact Fire Truck Platforms
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Solution Overview
Problem
The hydraulic power system in aerial fire truck platforms is bulky and heavy, occupying significant space and accounting for up to 30% of the platform's weight, limiting further lightweighting and space-saving efforts due to traditional design and manufacturing of components like hydraulic pumps, valves, and pipelines.
Innovation Solution
An integrated hydraulic power device is developed, featuring a compact design where a motor and hydraulic pump are housed within a hydraulic oil tank, with an integrated valve and oil port component, utilizing metal 3D printing for the valve body and non-metallic materials for the tank, reducing external pipelines and optimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional separate design of hydraulic components (pump, valve, tank, pipelines) is used, then each component can be manufactured independently with standard processes, but the overall system occupies large space and accounts for up to 30% of platform weight
Solution Approach 1:
The patent combines the hydraulic pump, control valve, and oil tank into a single integrated hydraulic power device. The pump and valve are mounted on a common base plate that is directly connected to the oil tank, eliminating the need for separate mounting structures and external pipelines. This integration reduces the overall system volume and weight while maintaining independent manufacturability of the modular unit.
Solution Approach 2:
The control valve is positioned within the oil tank structure, with the valve body partially embedded in the tank wall. The pump is mounted on the base plate that forms part of the tank assembly. This nested arrangement allows components to share structural space, reducing the total footprint of the hydraulic system without compromising manufacturing independence.
2Ease of manufacture
If traditional separate design of hydraulic components is used, then standard manufacturing processes can be applied to each component, but the system occupies significant platform space
Solution Approach 1:
The hydraulic pump, control valve, and oil tank are merged into a single compact assembly mounted on a common base plate. The pump and valve are positioned adjacent to each other with direct fluid connections, eliminating the need for external hydraulic pipelines. This integration dramatically reduces the space occupied by the hydraulic system on the aerial platform while maintaining standard manufacturing processes for each component within the modular unit.
Solution Approach 2:
The control valve is oriented with its flow passages arranged in a compact three-dimensional configuration that utilizes vertical space rather than horizontal spread. The valve body is positioned to overlap with the oil tank volume, and the pump is mounted vertically on the base plate, optimizing the use of available space in multiple dimensions rather than spreading components out in a single plane.
Data Source
AI summary
The present disclosure relates to an integrated hydraulic power device and a fire truck. The integrated hydraulic power device includes: an integrated valve including a valve body having an internal flow passage structure, a first mounting end and a second mounting end; a motor fixedly arranged at the first mounting end; a hydraulic oil tank fixedly arranged at the second mounting end; and a hydraulic pump located within the hydraulic oil tank and in drive connection with the motor, wherein the hydraulic pump has an oil suction port for drawing oil from the hydraulic oil tank, and the internal flow passage structure is communicated with the hydraulic oil tank and the hydraulic pump.