Manual Hydraulic Brake Release With Accumulator-Based Lowering Control
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Solution Overview
Problem
Existing hydraulic lowering devices for lifting equipment are difficult to operate, lack control over pressure in the hydraulic brake release chamber, and do not allow for a slow and controlled lowering of loads, posing risks to operators due to the need for precise adjustments and the potential for all-or-nothing pressure changes.
Innovation Solution
A hydraulic lowering device featuring a pressurized fluid accumulator, a pump, and a three-way pressure regulator, allowing for decoupling of pressurization and fluid injection, and enabling precise control of pressure in the hydraulic brake release chamber through a mechanical control input and manual actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a hydraulic lowering device with integrated reservoir and hand pump is used, then the device can be operated manually from the lifting bridge, but the operator experiences stress and fatigue due to the need for continuous precise pressure adjustment throughout the lowering duration
Solution Approach 1:
The hydraulic lowering device is divided into two independent functional units: a pressurization unit (hand pump and reservoir) and a control unit (pressure regulator with flow control valve). This segmentation allows the operator to perform pressurization and control functions separately, eliminating the need for continuous precise adjustment and reducing operator stress and fatigue.
Solution Approach 2:
A pressure regulator with flow control valve is introduced as an intermediary device between the hand pump and the hydraulic brake release chamber. This intermediary automatically maintains the desired pressure by controlling the fluid flow, eliminating the need for the operator to continuously adjust pressure and reducing manual intervention requirements.
2Productivity
If the pump flow is matched to the leakage flow rate to balance pressure in the hydraulic chamber, then the load can be lowered, but the operator must adjust pumping force and speed throughout the entire duration, causing stress and fatigue
Solution Approach 1:
The pressure regulator with flow control valve enables the hydraulic system to self-regulate pressure by automatically balancing pump flow and leakage flow. The system maintains desired pressure without requiring continuous operator adjustment of pumping force and speed, allowing the load to be lowered smoothly with minimal manual intervention.
3Speed
If a single additional action on the pump lever is taken to increase pressure, then the brake opens rapidly and the load drops suddenly, but this all-or-nothing reaction prevents controlled slow lowering
Solution Approach 1:
The pressure regulator with flow control valve provides continuous feedback control of the hydraulic pressure in the brake release chamber. By automatically adjusting the flow of hydraulic fluid based on pressure differential, the system prevents sudden pressure changes and all-or-nothing brake release, enabling controlled slow lowering of the load.
4Ease of operation
If the operator manages the lowering from the lifting bridge or top of the crane, then the lowering can be controlled, but the operator is in an uncomfortable and dangerous position at height
Solution Approach 1:
The control functions of the hydraulic lowering device are extracted from the lifting bridge control position and relocated to ground level. The pressure regulator with flow control valve enables the operator to control the lowering process from a safe position on the ground, eliminating the need to be at height while maintaining full control capability.
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 device allows for safe, controlled, and slow lowering of loads, reducing operator stress and fatigue by enabling precise pressure regulation and allowing operation from a comfortable position, thus enhancing safety and efficiency.
Implementation Method 1
a pump (3) connected to the reservoir (1) for injecting fluid present in the reservoir under pressure into the accumulator (2)
Implementation Method 2
the lowering device comprises a pressurized fluid accumulator (2), connected to the fluid reservoir (1)... a member for manually actuating the control input of the pressure regulator
Implementation Method 3
a washer spring configured to impose a pressure force on said plate in the direction of closing the brake
Implementation Method 4
a three-way pressure regulator (4) comprising a mechanical control input (5) for adjusting a set value
Implementation Method 5
a fluid inlet connected to the accumulator (2), a first fluid outlet (16) connected to the fluid outlet socket (18) of the lowering device
Data Source
Figure 1
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AI summary
Hydraulic lowering device for a safety brake of a lifting device, comprising a fluid reservoir (1), a fluid outlet (18), a pressurized fluid accumulator (2), a pump (3) connected to the reservoir for injecting the fluid from the reservoir under pressure into the accumulator, a three-way pressure regulator (4) having a mechanical control input, actuated via a handwheel (5), for setting a set value, a fluid inlet connected to the accumulator (2), a fluid outlet connected to the fluid outlet (18), and a drain connected to the reservoir (1). The three-way pressure regulator makes it possible to precisely and safely control the release, reinforcement and weakening of the brake. The dissociation between the creation, by pumping, of an energy reserve in the accumulator and the control of the lowering via the pressure regulator facilitates control.