Programmable Plunger Pump Control for Variable Hydraulic Output
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Solution Overview
Problem
Existing high-pressure hydraulic pumps are expensive, heavy, noisy, and cumbersome, and lack the ability to deliver hydraulic liquid at different controllable pressures and flows, requiring manual adjustment and being incompatible with existing tools and machines.
Innovation Solution
A system comprising a frameless electric motor, plunger-type pump, pressure sensor, and controller that controls the pump's valve opening and closing based on pressure and rotational position to deliver hydraulic liquid at different controllable pressures and flows, with a programmable delivery profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If a two-stage positive displacement pump is used to deliver high pressure hydraulic liquid, then the required pressure can be achieved, but the pump becomes expensive, heavy, and cumbersome
Solution Approach 1:
The invention uses a dynamic control system with an electric motor and programmable controller that adjusts the pump's operation in real-time. The controller modulates the electric motor's speed and the valve timing based on demanded hydraulic power, allowing a single-stage pump to achieve variable high pressures that previously required expensive two-stage pumps. This dynamic adaptation eliminates the need for complex mechanical pressure multiplication stages.
Solution Approach 2:
The invention replaces the mechanical two-stage pump system with an electrically controlled single-stage pump system. Instead of using mechanical gear stages to multiply pressure, the system uses an electric motor with programmable control to regulate hydraulic output. This substitution of mechanical complexity with electrical control achieves the same high-pressure function at lower manufacturing cost and weight.
2Stress or pressure
If a two-stage positive displacement pump is used to deliver high pressure hydraulic liquid, then the required pressure can be achieved, but the pump becomes noisy and cumbersome
Solution Approach 1:
The invention replaces the noisy mechanical two-stage pump system with an electrically controlled single-stage pump. The electric motor with programmable control operates more quietly than mechanical gear stages, while still achieving the required high pressures through electrical regulation of pump delivery rather than mechanical pressure multiplication.
3Stress or pressure
If existing high-pressure pumps are used, then high pressure delivery is achieved, but the pump can only deliver at one fixed specific flow
Solution Approach 1:
The invention implements a dynamic delivery system where the programmable controller continuously adjusts the electric motor speed and valve timing based on real-time hydraulic power demands. This allows the pump to vary both pressure and flow dynamically, adapting to different tool requirements rather than being fixed at a single flow rate. The system can smoothly transition between different pressure-flow combinations to match actual tool needs.
Solution Approach 2:
The invention creates a universal pump system that can serve multiple hydraulic tools with different pressure and flow requirements using a single pump. The programmable controller stores multiple delivery profiles for different tools and can switch between them, making one pump replace multiple specialized pumps. This multi-functionality achieves variable flow delivery while maintaining high pressure capability.
4Stress or pressure
If existing high-pressure pumps are used, then high pressure delivery is achieved, but manual adjustment is required for different pressures
Solution Approach 1:
The invention implements a self-regulating system where the programmable controller automatically manages pressure and flow adjustments based on pre-stored delivery profiles. Instead of requiring manual operator intervention to adjust pressures for different tools, the system self-adapts by selecting the appropriate profile and automatically configuring the pump parameters. The operator simply selects the tool type, and the system handles all pressure control automatically.
Solution Approach 2:
The invention uses a feedback control system with a pressure sensor that continuously monitors actual hydraulic pressure and feeds this information back to the controller. The controller compares the sensed pressure with the target pressure from the delivery profile and automatically adjusts the electric motor speed and valve timing to maintain the correct pressure. This closed-loop feedback eliminates manual adjustment requirements and ensures precise pressure control.
5Reliability
If a pump system is designed for specific tools, then optimal performance for that tool is achieved, but compatibility with other tools is lost
Solution Approach 1:
The invention creates a universal pump system with a programmable controller that stores multiple delivery profiles, each optimized for different hydraulic tools. The controller can select and switch between these profiles to match the connected tool's requirements, providing optimal performance for each tool while maintaining compatibility with various tool types. This multi-functionality allows one pump to replace multiple tool-specific pumps.
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 provides a cost-effective, lightweight, and silent pump capable of delivering hydraulic liquid at various pressures and flows, compatible with existing tools and machines, and allowing for easy programmable control.
Implementation Method 1
a pressure sensor 290 sensing pressure of the hydraulic liquid to be delivered
Implementation Method 2
an electric motor 100 comprising a rotor 110 and a stator 120
Implementation Method 3
a pump 200, the pump being a plunger-type pump and comprising a cam 210, a cam shaft 220, a plunger 230
Implementation Method 4
a valve 250, the valve 250 opening or closing an inlet 260 for the hydraulic liquid to the plunger chamber 240
Data Source
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AI summary
A system and a method for controlling a pump to deliver hydraulic liquid for a hydraulic tool or machine at different controllable pressures and flows are disclosed. The system comprises an electric motor (100) comprising a rotor (110) and a stator (120); a pump (200), the pump being a plunger-type pump and comprising a cam (210), a cam shaft (220), a plunger (230), a plunger chamber (240), and a valve (250), the valve (250) opening or closing an inlet (260) for the hydraulic liquid to the plunger chamber (240), the plunger chamber comprising an outlet (270) for the hydraulic liquid, the plunger (230) engaging the cam (210), and the cam shaft (220) being connected to the rotor (110); a pressure sensor (290) sensing pressure of the hydraulic liquid to be delivered; and a controller (300) comprising a processor (310), the processor (310) being configured to control the opening and closing of the valve (250) in relation to pressure sensed by the pressure sensor (290) and rotational position of the rotor (110) or cam (210), and the processor (310) being configured to control the rotational speed, rpm, of the motor (100), wherein the processor (310) is further configured to be programmable to set a delivery profile setting the duration of the valve (250) being closed and opened and the timing when to open or close of the valve (250) in relation to the rotation position of the rotor (110) or cam (210), the delivery profile comprising at least a predetermined pressure and flow relationship, over time, of the hydraulic liquid to be deliver.