Plunger Hydraulic Pump Control for Variable Pressure Delivery
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Solution Overview
Problem
Existing high-pressure hydraulic pumps are expensive, heavy, noisy, and cumbersome, and cannot deliver hydraulic liquid at variable pressures or flows, requiring manual adjustment and lacking programmable control.
Innovation Solution
A system comprising a frameless electric motor, plunger-type pump, pressure sensor, and controller that adjusts valve opening and closing based on pressure and rotor position to deliver hydraulic liquid at different predetermined and controllable pressures and flows, ensuring efficient and programmable operation.
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, noisy, and cumbersome
Solution Approach 1:
The pump system is divided into a first pump for initial pressurization and a second pump for final pressurization, with each pump operating at lower pressure levels than a single high-pressure pump would require. This segmentation allows the use of smaller, lighter components while achieving the same overall pressure output.
Solution Approach 2:
A pressure-controlled coupling mechanism acts as an intermediary between the two pumps, selectively connecting them based on pressure requirements. The coupling includes pressure-sensitive elements that automatically engage or disengage pump connections, enabling flexible operation modes (first pump only, second pump only, or both in series) without requiring a complex fixed two-stage structure.
2Stress or pressure
If existing high-pressure pumps are used, then high pressure delivery is achieved, but the pumps can only deliver at one fixed specific flow and require manual adjustment for different pressures
Solution Approach 1:
The pump system incorporates dynamic control capabilities where the coupling between pumps can be adjusted in real-time based on pressure and flow requirements. The pressure-controlled coupling mechanism allows the system to transition between different operational configurations, enabling variable pressure and flow delivery rather than fixed single-point operation.
Solution Approach 2:
The system can change operational parameters by selectively engaging different pump configurations. By controlling which pump(s) operate and how they are coupled, the system can deliver different pressure levels and flow rates, adapting to varying hydraulic demands without manual reconfiguration.
3Ease of manufacture
If a simple pump design is used, then manufacturing cost is reduced, but the pump cannot provide programmable control and demand-controlled hydraulic power
Solution Approach 1:
The system incorporates pressure sensing feedback mechanisms that automatically control the coupling between pumps. Pressure-sensitive elements monitor the hydraulic pressure and automatically engage or disengage pump connections, providing automated control without requiring complex electronic programming or control systems.
Solution Approach 2:
The pressure-controlled coupling mechanism is self-regulating, automatically adjusting the pump configuration based on system pressure conditions. This self-service capability eliminates the need for external control systems or programmable logic, maintaining simplicity while achieving automated demand-controlled operation.
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 variable pressures and flows, compatible with existing tools and machines, with programmable control and efficient energy use.
Implementation Method 1
a plunger-type pump and comprising a cam 210, a cam shaft 220, a plunger 230, a plunger chamber 240
Implementation Method 2
a valve 250, the valve 250 opening or closing an inlet 260 for the hydraulic liquid to the plunger chamber 240
Implementation Method 3
a pressure sensor 290 sensing pressure of the hydraulic liquid to be delivered
Implementation Method 4
an electric motor 100 comprising a rotor 110 and a stator 120
Data Source
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AI summary
A system and method delivering hydraulic liquid at different predetermined and controllable pressures for a hydraulic tool or machine is 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 (240) 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) configured to control the opening and closing of the valve (250) in relation to pressure sensed by the pressure sensor (300) and rotational position of the rotor (110) or cam (210), the controller (300) thereby controlling the volume and pressure of the hydraulic liquid to the outlet (270) and the load on the electric motor (100).