Redundant Pressure Compensation Valve Control With Low Pressure Loss
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Solution Overview
Problem
Traditional flow control systems face issues with pressure difference loss, delayed system response due to signal lag, energy waste from throttled pressure compensation valves, and loss of stable control when pressure sensors fail, especially in multi-actuator systems with fluctuating loads.
Innovation Solution
A flow control system incorporating a two-position three-way electromagnetic valve for complete opening of pressure compensation valves at high load locations, combined with digital and mechanical pressure compensation mechanisms to reduce pressure loss and maintain stability, using sensors and controllers for real-time adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a pressure compensation valve is used to maintain constant pressure difference across the valve, then flow control stability is improved, but additional pressure loss occurs
Solution Approach 1:
The patent replaces the traditional mechanical pressure compensation valve with a digital control system that uses pressure sensors, flow sensors, and a controller to calculate and adjust valve opening degree, eliminating the need for mechanical pressure balancing and reducing pressure loss while maintaining flow stability
Solution Approach 2:
The system implements feedback control by continuously monitoring pressure and flow parameters through sensors, comparing them with target values, and adjusting the valve opening degree in real-time to maintain stable flow control without the pressure loss associated with mechanical compensation valves
2Speed
If a pressure sensor and controller are used for digital pressure compensation, then system response speed is improved, but reliability decreases when sensors fail
Solution Approach 1:
The patent incorporates redundant mechanical pressure compensation mechanisms that are pre-configured to automatically activate when digital sensors fail, providing a backup control path that maintains system reliability while preserving the fast response benefits of digital control during normal operation
Solution Approach 2:
The system dynamically changes control parameters by switching between digital control mode (using sensor feedback) and mechanical control mode (using inherent pressure-balancing mechanics) based on the operational status of sensors, thereby maintaining both fast response and high reliability under different conditions
3Manufacturing precision
If pressure compensation valves are used in multi-actuator systems, then flow distribution is improved, but energy waste occurs when valves are throttled due to load fluctuation
Solution Approach 1:
The patent implements dynamic control of valve opening degrees based on real-time load detection and actuator position feedback, allowing the system to optimize flow distribution to multiple actuators while minimizing throttling losses by adjusting each valve's opening degree according to actual load requirements rather than using fixed mechanical compensation
4Stability of the object's composition
If traditional pressure compensation methods are used, then flow control is maintained, but system accuracy decreases when oil supply flow is insufficient
Solution Approach 1:
The system uses feedback from pressure sensors and flow sensors to continuously monitor actual flow conditions and adjust valve opening degrees accordingly, enabling accurate flow distribution even when total oil supply flow is insufficient by optimally allocating available flow to different actuators based on their actual needs
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 effectively reduces pressure loss and maintains stable flow control by enabling complete opening of pressure compensation valves under high loads and switching to mechanical compensation when digital sensors fail, ensuring continuous and accurate flow distribution.
Implementation Method 1
a first two-position three-way electromagnetic valve (6), wherein a port A of the first two-position three-way electromagnetic valve (6) is connected with a left control chamber of the first pressure compensation valve (4)
Implementation Method 2
the first pressure sensor and the second pressure sensor are configured for measuring pressures of the two chambers of the first hydraulic cylinder respectively
Implementation Method 3
the electric motor drives the pump to pump pressure oil in the oil tank to the port P of the first main valve
Data Source
AI summary
Disclosed is a flow control system for digital and mechanical redundant pressure compensation. On the basis of an original pressure compensation valve, two-position three-way electromagnetic valves are added to control the opening and closing of pressure compensation valves. Furthermore, pressure sensors and a controller are added, so that the system has a digital pressure compensation function. When the pressure sensor breaks down, the flow control system is switched to a mechanical compensation mode to achieve mechanical pressure compensation, the problem that system flow cannot be controlled when the sensor breaks down is solved, and the purpose of redundancy control is achieved. Moreover, the pressure compensation valve in the loop where the highest load is located can be controlled to be completely opened through the two-position three-way electromagnetic valve to reduce pressure loss of the valve port, and the pressure is not affected by load fluctuation.