Shovel Controller Proactive Boost Pressure Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power control devices for turbocharger engines in hydraulic shovels cannot quickly increase boost pressure to match rapid increases in hydraulic load, leading to issues like incomplete combustion, engine power shortages, and potential engine stops.
Innovation Solution
A shovel with a controller that proactively increases the discharge pressure of a supercharger by controlling flow control valves in the hydraulic system, allowing for voluntary increase in absorbing horsepower before hydraulic load is applied, thus ensuring timely boost pressure adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the boost pressure is increased only after hydraulic load increases, then the engine power can be maintained under normal conditions, but the boost pressure cannot be increased quickly enough to match rapid hydraulic load increases
Solution Approach 1:
The controller proactively increases the discharge pressure of the hydraulic pump before a load is applied to the hydraulic actuator by controlling a flow control valve to limit or block hydraulic oil flow. This preliminary action causes the engine load and boost pressure to increase in advance, so when the hydraulic load actually increases, the boost pressure can quickly match the load increase without delay, preventing incomplete combustion and engine power shortages.
2Power
If the discharge pressure of the hydraulic pump is increased by controlling flow control valves, then the absorbing horsepower can be voluntarily increased before hydraulic load application, but the hydraulic system complexity increases
Solution Approach 1:
The system uses the existing flow control valves in the hydraulic control system to serve dual purposes: their normal function of controlling hydraulic actuator operation, and an additional function of limiting or blocking hydraulic oil flow to increase pump discharge pressure and absorbing horsepower. This self-service approach allows the system to voluntarily increase power capacity before load application without adding separate dedicated components, thereby avoiding excessive system complexity.
3Reliability
If the engine load is increased in advance to raise boost pressure, then the engine revolution speed can be maintained during rapid load changes, but the fuel consumption increases
Solution Approach 1:
The controller dynamically adjusts the discharge pressure of the hydraulic pump based on real-time detection of hydraulic load changes. When a load increase is detected, the controller proactively increases discharge pressure by controlling the flow control valve to limit or block hydraulic oil flow. This dynamic adjustment ensures the engine load and boost pressure increase only when needed, maintaining engine revolution speed and preventing incomplete combustion, while minimizing unnecessary fuel consumption by avoiding continuous high-load 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
This solution enables the shovel to maintain engine revolution speed and prevent engine stops by quickly increasing boost pressure in response to hydraulic load changes, enhancing operational stability and performance.
Implementation Method 1
A turbocharger uses an exhaust gas of an engine to rotate a turbine and generate a pressure, and introduces the generated pressure into an induction system of the engine to supercharge the engine and increase the engine power
Implementation Method 2
The controller is configured to increase a boost pressure of the supercharger before a load is applied to the hydraulic actuator by controlling a specific flow control valve in the control valve system to limit or block the flow of the hydraulic oil discharged from the hydraulic pump and thereby increasing a discharge pressure of the hydraulic pump
Implementation Method 3
a hydraulic pump coupled to the internal-combustion engine
Implementation Method 4
a hydraulic actuator to be driven by a hydraulic oil discharged from the hydraulic pump
Data Source
AI summary
A shovel includes a lower traveling body, an upper rotating body mounted on the lower traveling body, an internal-combustion engine including a supercharger and being controlled at a constant revolution speed, a hydraulic pump coupled to the internal-combustion engine, a hydraulic actuator to be driven by a hydraulic oil discharged from the hydraulic pump, a control valve system including multiple flow control valves for controlling a flow of the hydraulic oil discharged from the hydraulic pump, and a controller that controls an absorbing horsepower of the hydraulic pump. The controller is configured to increase a boost pressure of the supercharger before a load is applied to the hydraulic actuator by controlling a specific flow control valve in the control valve system to limit or block the flow of the hydraulic oil discharged from the hydraulic pump and thereby increasing a discharge pressure of the hydraulic pump.