Smart Power Unit Control for Flexible Hydraulic Actuator Integration
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Solution Overview
Problem
Existing hydraulic systems face challenges in flexibility and integration with complex systems, requiring significant engineering effort due to limited features in electric control units, which are not adaptable to diverse and high-power applications.
Innovation Solution
A Smart Power Unit (SPU) with a hydraulic process computer, programmable logic processors, and a sensor board, integrated with a human-machine interface via a network, enabling flexible control and risk reduction through a Safety Integrity Level 2 architecture, directly managing actuators and valves without external devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional electric control units are used in hydraulic systems, then the system structure is simple, but the adaptability to complex and different hydraulic systems is poor
Solution Approach 1:
The control unit is designed with a programmable logic processor that can be configured through a standardized programming interface to perform different control functions. This allows the same hardware platform to adapt to various hydraulic system configurations and requirements, achieving multi-functionality without increasing physical complexity
Solution Approach 2:
The control unit employs programmable logic that can be dynamically reconfigured through software programming rather than fixed hardwired logic. This dynamic programmability enables the control unit to adapt to different hydraulic systems by loading appropriate control programs, resolving the contradiction between adaptability and structural simplicity
2Adaptability or versatility
If traditional electric control units with limited features are used, then the device complexity is low, but the integration capability in complex hydraulic systems is insufficient
Solution Approach 1:
The control unit is segmented into modular functional components including a programmable logic processor, communication interfaces, and control output stages. This modular architecture allows selective activation of features based on system requirements, enabling high integration capability while maintaining manageable complexity through organized functionality
Solution Approach 2:
A standardized programming interface acts as an intermediary between the user and the control unit's internal logic. This interface layer allows complex control functions to be programmed and configured without requiring direct manipulation of hardware complexity, enabling sophisticated integration capabilities while presenting a simple programming model
3Adaptability or versatility
If known electric control systems are adapted to complex hydraulic systems, then the adaptability improves, but strong engineering effort is required
Solution Approach 1:
The control unit incorporates self-configuration capabilities through standardized communication protocols and programming interfaces. The system can automatically detect and adapt to different hydraulic configurations, reducing the manual engineering effort required for adaptation while maintaining high flexibility through programmable control logic
Data Source
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AI summary
A hydraulic system comprising a hydraulic power pack (61) comprising a hydraulic pump (65), an electric motor (63) arranged to drive the hydraulic pump (65), and one or more valves (671, 672,..., 67n) connected to the hydraulic pump (65) and arranged to directly manage, by way of direct connections, one or more respective actuators. The hydraulic system (10) further comprises a hydraulic process computer (21) arranged to control the one or more actuators by way of said one or more valves (671, 672,..., 67n). An operation method of the system is also disclosed.