Parallel Hydraulic Valve Control Without Compensator Valves
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Solution Overview
Problem
Hydraulic systems in work vehicles often experience excessive energy consumption due to compensator valves creating unnecessary pressure drops, which reduces fuel economy and increases the load on the pump.
Innovation Solution
A system with parallel hydraulic loads and adjustable flow control valves, controlled by a computing system that determines and manages pressure across each load to optimize flow rates and minimize pump pressure, eliminating the need for compensator valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If compensator valves are used to maintain predetermined pressure drop across flow control valves, then pressure control is improved, but energy consumption increases and fuel economy deteriorates
Solution Approach 1:
The patent removes compensator valves from the hydraulic system entirely. Instead of using compensator valves to maintain pressure drops, the system uses a pump controller that adjusts pump discharge pressure dynamically based on real-time pressure sensor feedback from each hydraulic load, eliminating the energy-wasting pressure drops caused by compensator valves
Solution Approach 2:
The patent implements a feedback control system where pressure sensors monitor the actual pressure at each hydraulic load, and this information is fed back to the pump controller. The controller continuously adjusts the pump discharge pressure to match the minimum required pressure for each load, replacing the open-loop pressure maintenance approach of compensator valves with a closed-loop adaptive system
2Ease of operation
If compensator valves create predetermined pressure drop across flow control valves, then flow control is maintained, but pump load increases and fuel economy worsens
Solution Approach 1:
The patent transitions from static pressure drop maintenance by compensator valves to dynamic pressure adjustment. The pump controller continuously varies the pump discharge pressure based on real-time demands of hydraulic loads, allowing flow control to adapt dynamically to actual system conditions rather than maintaining fixed pressure drops that waste energy
Solution Approach 2:
The patent changes the operating parameters of the hydraulic system by eliminating fixed pressure drops and implementing variable pressure control. The pump discharge pressure is adjusted as a variable parameter based on load requirements, replacing the constant pressure drop approach that caused energy losses
3Reliability
If multiple compensator valves are used in parallel hydraulic loads, then individual pressure control is achieved, but system complexity and device complexity increase
Solution Approach 1:
The patent makes the pump controller a universal control device that manages pressure for multiple parallel hydraulic loads through a single feedback control system. Instead of requiring separate compensator valves for each load, one intelligent pump controller with multiple pressure sensor inputs provides individual pressure control for all loads, reducing component count and system complexity
Solution Approach 2:
The patent merges the functions of multiple compensator valves into a single pump control system. By combining pressure sensing from all hydraulic loads and centralizing control in the pump controller, the system achieves individual pressure control for each load while eliminating the need for separate compensator valves at each load
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
This approach reduces energy consumption and improves fuel economy by optimizing hydraulic fluid flow and pressure management, allowing the pump to discharge at minimum necessary pressure without compensator valves.
Implementation Method 1
a first pressure sensor configured to capture data indicative of a first pressure of the hydraulic fluid being supplied to the first hydraulic load by the first flow control valve. In addition, the work vehicle includes a second pressure sensor configured to capture data indicative of a second pressure of the hydraulic fluid being supplied to the second hydraulic load by the second flow control valve
Implementation Method 2
a first flow control valve defining an adjustable orifice, with the first flow control valve fluidly coupled to the first fluid conduit upstream of the first hydraulic load such that the first flow control valve is configured to control a flow rate of the hydraulic fluid to the first hydraulic load
Data Source
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AI summary
A work vehicle (10) comprises a computing system (148) configured to receive first and second input associated with controlling the operation of the first and second hydraulic load (36, 38), respectively. Furthermore, the computing system (148) is configured to control the operation of a first or second flow control valve (114, 118) corresponding to the one of the first or second hydraulic loads (36, 38) associated with the greater hydraulic fluid pressure such that the corresponding adjustable orifice (116, 118) is at a maximum flow position. Additionally, the computing system (148) is configured to determine the first and second pressures of the hydraulic fluid being supplied to the first or second hydraulic loads (36, 83). Moreover, the computing system (148) is configured to control the operation of the first or second flow control valve (114, 118) corresponding to another of the first or second hydraulic loads (36, 38) based on the corresponding received first or second input and the determined first and second pressures.