Rotary Encoder Pump Speed Detection for Hydraulic Flow Control
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Solution Overview
Problem
Commercial vehicle bodies, such as tipper vehicles, require complex adjustment measures to achieve optimized hydraulic fluid volume flows due to varying idling speeds, gear ratios, and different types of pumps used across different manufacturers, leading to inefficiencies and increased fuel consumption.
Innovation Solution
A rotary encoder is integrated to detect the current pump speed and transmit this information to a control device, which adjusts the engine speed to match the setpoint pump speed, eliminating the need for complex parameterizations by using pump identification information to determine optimal hydraulic fluid flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If complex adjustment measures and parameterizations are implemented to adapt to different idling speeds, gear ratios, and pump types, then the hydraulic system can achieve optimized fluid volume flows, but the device complexity and commissioning effort increase significantly
Solution Approach 1:
The system automatically detects pump speed using a rotary encoder and self-regulates engine speed through the control device without requiring manual parameterization. The system serves itself by adapting to different operating conditions (different idling speeds, gear ratios, pump types) through automatic detection and feedback control, eliminating the need for complex commissioning adjustments
Solution Approach 2:
The rotary encoder provides continuous feedback on actual pump speed to the control device, which compares it with the desired pump speed and automatically adjusts engine speed accordingly. This closed-loop feedback system enables the hydraulic system to maintain optimized fluid volume flows across varying operating conditions without manual intervention or complex parameter settings
2Loss of energy
If the engine speed is continuously adjusted to match hydraulic fluid requirements, then fuel consumption and emissions are reduced, but the control system complexity increases
Solution Approach 1:
The control device performs multiple functions: it detects pump speed via the rotary encoder, determines desired pump speeds based on operating state, compares actual vs. desired speeds, and controls engine speed adjustment. This multi-functional approach achieves fuel optimization without requiring separate dedicated control systems for each function
Solution Approach 2:
The system dynamically changes the engine speed parameter based on hydraulic fluid requirements and operating state. By continuously adjusting this key parameter in response to actual vs. desired pump speed differences, the system optimizes fuel consumption while maintaining hydraulic performance
3Ease of operation
If a rotary encoder is integrated to detect pump speed and enable automatic control, then the need for complex parameterizations is eliminated, but the initial device complexity and cost increase
Solution Approach 1:
The rotary encoder replaces manual mechanical parameterization and adjustment mechanisms with an electronic detection and control system. Instead of physically adjusting parameters for different pump types and conditions, the system uses electronic sensing and automated control, simplifying commissioning despite the added electronic components
Solution Approach 2:
The rotary encoder acts as an intermediary between the mechanical pump system and the electronic control system. It converts mechanical pump speed into an electrical signal that the control device can process, enabling automatic control without direct mechanical linkages or manual parameter settings
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 solution ensures optimal hydraulic fluid delivery volume flows for each operating state of the hydraulic consumer system, reducing fuel consumption and eliminating the need for complex parameterizations, thereby improving operational efficiency.
Implementation Method 1
a rotary encoder which detects a current pump speed and emits a rotary encoder signal indicating the pump rotation
Data Source
Figure 1~2c
AI summary
The vehicle structure has a rotary encoder (16) for providing a rotary encoder signal for detecting the actual pumping rotation speed. The rotary encoder is aligned to transfer the rotary encoder signal to a controller (7,12). The controller is aligned to process the rotary encoder signal to detect a rotation speed difference between the actual pump rotation speed and reference pump rotation speed related to the adjusted operating state of the hydraulic consumer system. An engine controller (37) is provided to induce change of the engine speed to reduce or eliminate the rotation speed.