Electric Motor Windings Heat Hydraulic Fluid
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Solution Overview
Problem
In cold environments, hydraulic pumps with electric motors face difficulties in starting up due to high viscosity of hydraulic fluid, leading to inefficiencies such as continuous operation reducing pump life and bleed air efficiency, as existing methods either continuously run the pump or provide continuous bleed air.
Innovation Solution
A hydraulic pump system with an electric motor that uses windings as a temperature sensor to generate heat and a controller to manage viscosity by selectively providing power and bleed air, reducing fluid viscosity only when needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the pump is continuously run to decrease fluid viscosity, then the pump can startup rapidly, but the life of the pump and electric motor decreases
Solution Approach 1:
The system uses periodic heating cycles instead of continuous operation. The controller activates the heating element only when cold temperature is detected, maintaining the pump in a stationary state during warm periods and providing periodic warmth to reduce fluid viscosity during cold conditions, thereby extending pump life while enabling rapid startup when needed.
Solution Approach 2:
The system replaces mechanical continuous operation with an electrical heating solution. Instead of continuously running the pump mechanically to generate heat through operation, an electrical heating element is used to directly heat the hydraulic fluid, reducing mechanical wear while achieving the same viscosity reduction goal.
2Temperature
If continuous bleed air is provided to heat the fluid, then the fluid viscosity decreases, but the efficiency of the bleed air source decreases
Solution Approach 1:
The system uses the pump's own electric motor as the heat source. The heating element is powered by the pump's electrical system, making the system self-sufficient without requiring external bleed air from the turbine engine. This eliminates the efficiency penalty associated with continuous bleed air extraction while maintaining the ability to heat fluid when needed.
Solution Approach 2:
The system changes the heating method from thermal energy transfer via bleed air to direct electrical heating. This parameter change from gas-phase convective heating to electrical resistive heating provides more efficient and controllable temperature management without the penalties of continuous bleed air usage.
3Temperature
If power is continuously provided to windings to generate heat, then fluid viscosity is reduced, but energy efficiency decreases
Solution Approach 1:
The controller implements periodic heating by monitoring temperature and activating the heating element only when cold conditions are detected. This on-demand heating approach reduces energy consumption compared to continuous power application, while still maintaining the ability to reduce fluid viscosity rapidly when cold temperatures are present.
Solution Approach 2:
The system uses temperature feedback from the pump to control heating activation. The controller continuously monitors fluid or ambient temperature and activates the heating element only when the temperature indicates cold conditions, creating a closed-loop control system that optimizes energy usage by heating only when necessary.
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
Efficiently reduces hydraulic fluid viscosity for rapid startup, extending pump life and improving energy efficiency by heating the fluid only when necessary, thereby enhancing the pump's performance in cold conditions.
Implementation Method 1
power sufficient to provide a stall torque to the electric motor has been used to generate heat using the windings of the electric motor
Implementation Method 2
The windings are used as the temperature sensor, in one example
Implementation Method 3
Providing a continuous flow of bleed air decreases the efficiency of the source providing the bleed air
Data Source
AI summary
A hydraulic pump system is provided that includes a pump driven by an electric motor. The electric motor includes windings that receive power from a power source. In one example, a temperature sensor is arranged in proximity to hydraulic fluid associated with the pump, such as at an input of the pump. In another example, the temperature sensor measures the ambient temperature to predict the viscosity of the pump based upon cool down rates of the system. A controller monitors a temperature at the temperature sensor and commands power to be provided to the windings to generate heat. Electric motor power consumption can be monitored to determine viscosity. The heat reduces the viscosity of the hydraulic fluid. Bleed air may be selectively provided to a casing associated with the hydraulic fluid in response to a command from the controller. The controller actuates a valve to regulate the flow of bleed air to the casing to provide supplemental heat to the heat provided by the windings. In this manner, the viscosity of the hydraulic fluid is more efficiently managed to provide desired startup of the pump in cold conditions.