Spool Displacement Control for Construction Machine Efficiency
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing construction machines face a trade-off between regeneration efficiency and fuel efficiency due to compromised orifice design, leading to deteriorated regeneration efficiency and increased pressure loss in operating modes.
Innovation Solution
An apparatus and method for controlling spool displacement in construction machines, which adjusts the quantity of spool displacement based on the joystick operation and current main pump pressure, using an electronic proportional pressure reducing valve to optimize orifice area and reduce pressure loss, thereby improving regeneration and fuel efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the orifice area is increased to reduce back pressure in operating mode, then fuel efficiency is improved, but regeneration efficiency deteriorates due to insufficient flow rate to cylinder
Solution Approach 1:
The patent applies dynamics by making the orifice area variable rather than fixed. The control unit dynamically adjusts the spool displacement quantity based on real-time detection of machine state (operating mode vs. regeneration mode), thereby changing the orifice area adaptively. This resolves the contradiction by allowing large orifice area during operating mode for fuel efficiency while maintaining small orifice area during regeneration mode for regeneration efficiency.
Solution Approach 2:
The patent changes the parameter of orifice area based on operating conditions. By detecting whether the machine is in operating mode or regeneration mode, the control unit adjusts the spool displacement to change the orifice area parameter accordingly. This parameter change strategy allows optimization of both fuel efficiency (large orifice) and regeneration efficiency (small orifice) at different operational phases.
2Productivity
If the orifice area is decreased to improve regeneration efficiency, then regeneration efficiency is improved, but pressure loss increases in operating mode causing fuel efficiency to deteriorate
Solution Approach 1:
The system dynamically adjusts the orifice area based on real-time machine state detection. During regeneration mode, the control unit maintains small spool displacement to keep orifice area small for high regeneration efficiency. During operating mode, it increases spool displacement to enlarge orifice area and reduce pressure loss, thereby improving fuel efficiency. This dynamic adaptation resolves the contradiction between the two efficiency requirements.
Solution Approach 2:
The patent changes the orifice area parameter according to operational mode. By detecting machine state and adjusting spool displacement, the system optimizes the orifice area parameter to be small during regeneration mode for high regeneration efficiency and large during operating mode for low pressure loss and high fuel efficiency.
3Adaptability or versatility
If a fixed orifice area is designed to compromise between operating mode and regeneration mode, then both modes can operate, but regeneration efficiency deteriorates and pressure loss occurs in operating mode
Solution Approach 1:
The patent transforms the fixed orifice area design into a dynamic adjustable system. By using a control unit that detects machine state and adjusts spool displacement accordingly, the orifice area becomes variable rather than fixed. This allows the system to achieve optimal performance in both operating mode and regeneration mode, eliminating the compromise required by fixed design.
Solution Approach 2:
The system performs self-adjustment based on its own operational state. The control unit automatically detects whether the machine is in operating mode or regeneration mode and autonomously adjusts the spool displacement to optimize orifice area, eliminating the need for manual intervention or compromise in fixed design.
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 solution enhances regeneration efficiency and fuel efficiency by dynamically adjusting spool displacement according to the machine's operational state, reducing pressure loss and improving convenience by eliminating the need for separate driver operations.
Implementation Method 1
a pilot gear pump configured to discharge working oil for driving the main control valve
Implementation Method 2
using an electronic proportional pressure reducing valve to optimize orifice area and reduce pressure loss
Data Source
AI summary
Provided are an apparatus and a method for controlling spool displacement of a construction machine, which are capable of improving regeneration efficiency of the construction machine, and improving a fuel efficiency characteristic of the construction machine by reducing pressure loss in the operating mode by adjusting the quantity of spool displacement in a regeneration mode when a current pressure of a main pump is less than a predetermined operating pressure, and determining whether the construction machine is in an operating mode or the regeneration mode in real time according to an operating angle of a joystick and the current pressure of the main pump when the current pressure of the main pump is greater than or equal to the predetermined operating pressure to variably change the quantity of spool displacement in the operating mode.