Construction Machine Pump Control System for Hydraulic Efficiency
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Solution Overview
Problem
Construction machines experience inefficiencies in energy transfer due to hydraulic friction losses, leading to actuators operating at only 20% of engine output, and varying loads cause insufficient flow rates in pump systems.
Innovation Solution
A pump control operating system with a one-to-one pump system for high-energy actuators and an auxiliary control valve system for lower-energy actuators, where valves allow for dynamic redistribution of working oil to ensure consistent supply and share resources when needed, using a combination of first, second, third, and fourth interrupting valves to manage flow between pumps and actuators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a one-to-one pump system is used for each actuator, then energy efficiency is improved and hydraulic friction losses are reduced, but the system complexity increases and cost increases
Solution Approach 1:
The hydraulic system is segmented into multiple independent one-to-one pump-actuator pairs, with each pump dedicated to a specific actuator. This segmentation eliminates the need for a centralized pump distributing oil through complex valve networks, thereby reducing hydraulic friction losses while maintaining manageable system complexity through modular architecture
Solution Approach 2:
The pumps are designed with multi-functionality to handle various operational modes. Each pump can independently supply working oil to its dedicated actuator, and the system as a whole can adapt to different load conditions by regulating each pump's output, providing universal applicability across diverse construction machine operations
2Loss of energy
If pumps are dedicated to respective actuators in a one-to-one system, then energy efficiency increases, but when over load is applied the flow rate becomes insufficient
Solution Approach 1:
The pump control system incorporates dynamic flow regulation capabilities where each pump's discharge flow can be independently adjusted based on real-time actuator load requirements. This dynamic control ensures that sufficient flow rate is maintained even under over load conditions while optimizing energy efficiency during normal operation
Solution Approach 2:
The system changes operational parameters by regulating the discharge flow rate of each pump according to the specific load demands of its dedicated actuator. This parameter adjustment allows the system to maintain adequate flow under varying load conditions, including over load scenarios, while preserving energy efficiency
3Loss of energy
If the number of hydraulic elements is reduced in a one-to-one pump system, then hydraulic friction losses decrease, but the ability to distribute working oil to multiple actuators simultaneously is limited
Solution Approach 1:
The hydraulic distribution function is segmented across multiple independent pump-actuator pairs, eliminating the need for complex centralized distribution valves. Each pump directly supplies its dedicated actuator, reducing hydraulic friction losses while maintaining the versatility to operate multiple actuators simultaneously through parallel independent supply lines
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 configuration enhances energy efficiency by reducing engine losses and ensures smooth operation of actuators by supplementing flow rates, particularly for actuators requiring large amounts of working oil, thereby optimizing engine output.
Implementation Method 1
The hydraulic pumps pressure working oil and supply the pressured working oil to respective actuators
Implementation Method 2
a first interrupting valve installed in a hydraulic pressure line connecting the boom pump for driving the boom cylinder and a cylinder rod of the boom cylinder to allow the supply of the working oil; and a second interrupting valve connected to a hydraulic pressure line connecting the boom pump and the cylinder rod of the boom cylinder to allow the supply of the working oil to the auxiliary control valve system
Data Source
AI summary
The present disclosure is a construction machine, such as an excavator, which comprises a plurality of hydraulically driven actuators, in which some of the actuators are provided in a one-to-one pump system where hydraulic pumps are connected to the respective actuators such that a working fluid is supplied from the respective pumps, and the remaining actuators are provided in an auxiliary control valve system where the working fluid is distributed by an auxiliary control valve connected to one or more pumps. When an amount of the working fluid of an actuator associated with the auxiliary control valve is insufficient, the actuator associated with the auxiliary control valve is connected to a pump of the one-to-one pump system to share the pump of the one-to-one pump system.