Pilot Control Unit Architecture for Universal Hydraulic Valve Drives
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Solution Overview
Problem
Existing hydraulic valve systems face logistical challenges due to the need for individual electronics reprogramming and robust design for each application, leading to high spare parts demands and susceptibility to mechanical loads, especially in harsh environments.
Innovation Solution
A pilot control unit is introduced to handle parametrization and control functions, moving intelligence from the valve drive to the pilot control unit, allowing a single unit to manage multiple valve drives with a bidirectional data transmission and emergency power supply, reducing the need for individual electronics and enhancing resilience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electronics are integrated into each valve drive for individual parametrization and control, then control functionality and adaptability are improved, but device complexity and susceptibility to mechanical loads increase
Solution Approach 1:
The patent extracts the electronics from the valve drive and places them in a separate, protected location. The valve drive retains only the power end stage and actuator, while the electronics are relocated to a control unit that is mechanically protected from harsh operating conditions. This separation reduces the complexity of the valve drive itself while maintaining full parametrization capability in the relocated electronics.
Solution Approach 2:
The patent introduces a communication interface as an intermediary between the protected electronics and the valve drive. This interface transmits control signals and data between the two locations, allowing the electronics to remain in a protected environment while still controlling the valve drive. The intermediary enables the separation of functions without compromising control capability.
2Reliability
If robust electronics design is implemented in valve drives to withstand mechanical loads, then reliability under harsh conditions is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent extracts the electronics from the mechanically stressed valve drive environment and relocates them to a protected location. This eliminates the need to design robust, mechanically resistant electronics for the valve drive, thereby simplifying manufacturing while maintaining reliability through the protected location of the electronics.
Solution Approach 2:
The patent provides beforehand protection for the electronics by locating them in a mechanically protected environment. This prior cushioning approach prevents mechanical loads from reaching the electronics in the first place, rather than requiring the electronics to withstand such loads. This simplifies manufacturing while ensuring reliability.
3Adaptability or versatility
If individual valve drives are parameterized for specific applications, then application-specific performance is improved, but logistics complexity and spare parts requirements increase
Solution Approach 1:
The patent makes the valve drive mechanically universal by removing application-specific electronics from it. The standardized valve drive with power end stage and actuator can be used across multiple applications, while application-specific parametrization is achieved through software configuration in the relocated electronics. This universality reduces the variety of physical components needed, thereby reducing spare parts inventory requirements.
Solution Approach 2:
The patent enables application-specific optimization through parameter changes in the relocated electronics rather than through physical modifications to the valve drive. By storing different parameter sets in the electronics and selecting them based on the application, the system achieves adaptability without requiring different physical valve drive configurations, thus reducing spare parts requirements.
4Extent of automation
If control functions are distributed to individual valve drives, then system autonomy is improved, but vulnerability to mechanical damage increases
Solution Approach 1:
The patent extracts the control functions from the mechanically exposed valve drive and relocates them to a protected control unit. The valve drive retains only actuation capability, while intelligent control functions are performed remotely in a mechanically protected environment. This maintains system automation while protecting control functions from mechanical damage.
Solution Approach 2:
The patent introduces a communication interface as an intermediary that enables distributed control capability without requiring the control electronics to be physically present at the valve drive. The intermediary transmits control signals and feedback data, allowing automated control functions to operate from a protected location, thereby reducing vulnerability to mechanical damage.
Data Source
AI summary
A pilot control unit is for at least one valve drive of a hydraulic valve with a valve slide. The valve slide can be adjusted by the valve drive, in order to supply hydraulic lines with hydraulic fluid through the hydraulic valve. The pilot control unit is set up to supply electronics and a power end stage for actuating an electrical actuator of the valve drive with electrical energy and operating commands and there is a parametrization module in the pilot control unit for this purpose, in which operating parameters for the operation of the at least one hydraulic valve by the valve drive thereof are stored.