Multi-pump System Flow Diversion for Fuel Efficiency
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Solution Overview
Problem
Hydraulic systems using open-center valves and fixed-displacement gear pumps are inefficient due to wasted power from continuous flow when not needed, leading to reduced fuel efficiency and increased fuel consumption.
Innovation Solution
A work vehicle equipped with a pump group comprising two fixed-displacement pumps in parallel, an open-center directional control valve, an electro-hydraulic diverter, and a controller that diverts flow from the second pump to the reservoir based on speed or pressure thresholds, allowing for manual operator control to optimize flow usage and reduce hydraulic power wastage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If open-center valves and fixed-displacement gear pumps are used, then system simplicity and contamination tolerance are improved, but fuel efficiency deteriorates due to continuous flow wastage
Solution Approach 1:
The hydraulic system is segmented into multiple pumps (first pump and second pump) with independent control. The second pump can be selectively deactivated or have its flow diverted when not needed, while the first pump continues to operate. This segmentation allows energy-saving control without compromising the overall system simplicity and contamination tolerance provided by the fixed-displacement gear pump architecture.
2Ease of operation
If full pump flow is run through open-center valves, then continuous fluid flow and system simplicity are maintained, but power efficiency deteriorates
Solution Approach 1:
The system transitions from static continuous flow operation to dynamic flow management. A control mechanism dynamically adjusts the operation of the second pump based on actual hydraulic demand, enabling the system to switch between full flow mode and reduced flow mode. This dynamic control improves power efficiency while maintaining the ease of operation and continuous flow capabilities when needed.
3Productivity
If a second fixed-displacement pump is added in parallel, then flow availability and productivity are improved, but energy wastage and system complexity increase
Solution Approach 1:
The control system automatically manages the operation of the second pump based on detected hydraulic demand. When sufficient flow is available from the first pump alone, the second pump is deactivated or its flow is diverted, eliminating energy wastage. When additional flow is needed for high-productivity operations, the second pump is activated. This self-service control enables the system to optimize between productivity and energy consumption without requiring complex manual intervention.
Data Source
AI summary
A work vehicle has a pump group with two fixed-displacement pumps, an electro-hydraulic diverter openable to divert flow from one of the pumps to a fluid reservoir, and a controller configured to command the diverter to open.