Mobile Hydraulic Generator with Segmented Pumps and Proportional Valve
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Solution Overview
Problem
Swash type hydraulic pumps face challenges in rapidly compensating for pressure loss and are costly due to complex structures, making them unsuitable for devices with varying flow rates, such as mobile robots, and motor efficiency is compromised when speed is rapidly changed.
Innovation Solution
A mobile hydraulic generator system comprising n pumps and motors, a proportional hydraulic control valve, pressure sensor, and hydraulic servo loop controller to rapidly respond to fluid flow and pressure changes, ensuring efficient control of hydraulic pressure and motor RPM.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a swash type pump is used to control discharged amount of fluid, then mechanical control is achieved without electronic circuit, but pressure compensation is slow and structure is complicated
Solution Approach 1:
The system divides the hydraulic control into multiple independent pump units (first pump and second pump) with different functions. The first pump handles pressure supply while the second pump handles flow control, separating the mechanical control function from pressure compensation function to achieve both simplicity and rapid response.
Solution Approach 2:
A proportional control valve is introduced as an intermediary component between the pumps and the hydraulic motor. This valve enables precise electronic control of hydraulic parameters without requiring complex mechanical feedback mechanisms in the pumps themselves, resolving the contradiction between mechanical simplicity and control speed.
2Adaptability or versatility
If motor speed is rapidly changed to control flow rate variation, then flow rate control is achieved, but motor efficiency is significantly deteriorated
Solution Approach 1:
The system dynamically adjusts the operating mode between two pumps based on real-time hydraulic demands. The controller selectively activates the first pump for pressure-critical operations and the second pump for flow-critical operations, optimizing motor efficiency across varying load conditions while maintaining adaptability.
Solution Approach 2:
The system changes operational parameters by switching between different pump configurations and adjusting proportional control valve positions. This allows continuous adjustment of hydraulic output parameters (pressure and flow) without requiring rapid motor speed changes, thereby maintaining motor efficiency while achieving flow rate adaptability.
3Reliability
If a high performance swash type pump is used, then pressure control is improved, but cost increases significantly
Solution Approach 1:
The hydraulic system is segmented into two separate pump units with specialized functions. Instead of using one expensive high-performance swash pump to handle all requirements, the system uses a simpler first pump for pressure supply and a second pump for flow control, significantly reducing manufacturing costs while maintaining pressure control reliability through the proportional control valve.
Solution Approach 2:
The system uses standard, readily available pump designs rather than custom high-performance swash pumps. By combining multiple standard pumps with electronic proportional control, the system achieves equivalent or superior pressure control performance at lower cost, making the solution more economically viable for mobile robot applications.
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 achieves rapid response and high efficiency, miniaturizing equipment while maintaining cost-effectiveness for mobile robots by distributing fluid flow and controlling motor and pump operations efficiently.
Implementation Method 1
a proportional hydraulic control valve to control output hydraulic pressure according to the amount of the hydraulic fluid
Implementation Method 2
a pressure sensor to detect the output hydraulic pressure
Implementation Method 3
a flow generator including n pumps operated by n motors to generate an amount of a hydraulic fluid
Data Source
AI summary
A flow generator includes pumps operated by motors to generate an amount of a hydraulic fluid, a proportional hydraulic control valve to control output hydraulic pressure according to the amount of the hydraulic fluid, a pressure sensor to detect the output hydraulic pressure, and a hydraulic servo loop controller to which a required hydraulic pressure and a required amount of fluid are input by a user. Based on a feedback signal representing the output hydraulic pressure, the controller generates a pressure control signal for controlling the proportional hydraulic control valve based on the required hydraulic pressure and a change in the output hydraulic pressure. It also generates an RPM input signal for controlling a motor's RPM.