Predictive Hydraulic Pressure and Flow Control for Energy Efficiency
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Hydraulic systems in industrial applications often operate at sub-optimal pressure ranges, leading to unnecessary energy expenditure and decreased accuracy in processing, due to binary control and lack of predictive flow and pressure management.
Innovation Solution
Implementing a variable frequency drive and inverter duty motor for power sources, coupled with a pressure transducer and flow rate sensor, to enable predictive flow and pressure control, along with a motion profile plan based on sensor readings and hydraulic characteristics, to optimize hydraulic fluid usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If binary control is used for hydraulic systems, then device complexity is reduced, but energy efficiency deteriorates due to sub-optimal pressure ranges
Solution Approach 1:
The patent applies dynamics by transitioning from static binary control to dynamic continuous pressure control. The system uses a variable frequency drive (VFD) to continuously adjust motor speed and an adjustable ratio divider to dynamically vary hydraulic pressure output, enabling the system to adapt pressure levels to actual workload requirements and eliminate energy-wasting high-pressure idle operation
Solution Approach 2:
The patent implements parameter changes by modifying key hydraulic parameters from fixed binary states to continuously variable parameters. The system changes motor speed parameter via VFD control and pressure ratio parameter via adjustable ratio divider, allowing smooth transitions between operating states to optimize energy efficiency across different production demands
2Device complexity
If binary control is used for hydraulic systems, then device complexity is reduced, but manufacturing precision deteriorates due to decreased accuracy
Solution Approach 1:
The system uses dynamic continuous adjustment of pressure and flow parameters to achieve precise control over hydraulic actuator motion. The adjustable ratio divider provides fine-grained pressure control, while the VFD enables precise speed regulation, together delivering the manufacturing precision needed for accurate part production
Solution Approach 2:
The patent incorporates feedback mechanisms through sensors that monitor actual pressure, flow, and position parameters. This feedback is fed back to the control system to continuously adjust VFD output and ratio divider settings, ensuring manufacturing precision is maintained through closed-loop control
3Use of energy by moving object
If predictive flow and pressure control is implemented, then energy efficiency is improved, but device complexity increases
Solution Approach 1:
The system implements preliminary action through demand forecasting that predicts future hydraulic requirements based on production schedules and historical data. This allows the control system to proactively adjust motor speed and pressure settings before peak demand occurs, optimizing energy efficiency through anticipatory control rather than reactive response
Solution Approach 2:
The patent uses an intermediary control architecture that sits between the hydraulic power unit and the actuators. This intermediary layer includes the VFD, adjustable ratio divider, and control system that mediates between power generation and power consumption, enabling sophisticated energy optimization without requiring complete system redesign
4Duration of action of stationary object
If excess pressure scenarios are minimized, then system longevity is improved, but pressure control complexity increases
Solution Approach 1:
The system applies dynamics by continuously adapting pressure output to match actual system requirements rather than maintaining constant high pressure. The adjustable ratio divider dynamically varies pressure transmission ratio, and the VFD dynamically adjusts motor speed, together preventing excess pressure scenarios that would accelerate component wear and extend system longevity
Solution Approach 2:
The control system implements self-service by automatically monitoring system conditions and adjusting pressure and flow parameters to prevent damaging excess pressure scenarios. The system serves itself by detecting when high pressure is not needed and reducing pressure output accordingly, eliminating the need for external intervention to protect against pressure-related failures
Data Source
AI summary
Methods and apparatus to manage hydraulic systems are disclosed. A disclosed example apparatus for controlling a hydraulic system to process a workpiece includes interface circuitry, machine readable instructions, and programmable circuitry to be programmed by the machine readable instructions to determine pressure requirements and flow requirements for a plurality of hydraulic devices of the hydraulic system based on a sequence of operations to be performed by the hydraulic devices, predict flow of hydraulic fluid based on the pressure requirements and the flow requirements, and generate a motion profile plan for a motor powering the hydraulic system based on the predicted flow.