Valve Current Calibration for Consistent Sweep Timing
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Solution Overview
Problem
The calibration of valve opening position current values in hydraulic circuits of work machines, such as hydraulic excavators, is inefficient due to varying sweep times across different valves, leading to inconsistencies in work conditions and reduced accuracy.
Innovation Solution
A valve calibration system that predicts calibration values based on historical data and specific valve characteristics, sets a sweep starting current value to achieve a consistent time to reach the calibration current, and adjusts the current application rate to ensure precise calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a uniform sweep starting current value is set for all valves, then the calibration process is simplified, but the sweep time to reach valve opening position current value varies significantly across different valves, reducing calibration accuracy and work standardization
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting the sweep starting current value based on the specific valve being calibrated. Instead of using a uniform current value for all valves, the system modifies the starting current parameter according to each valve's characteristics, ensuring consistent sweep times and improving calibration accuracy while maintaining operational simplicity through automated parameter adjustment.
2Ease of operation
If the sweep of applied current starts from zero and increases at a predetermined rate, then the calibration process is straightforward, but the calibration work takes excessive time, reducing work efficiency
Solution Approach 1:
The patent applies preliminary action by rapidly increasing the applied current from zero to the sweep starting current value before beginning the calibrated sweep. This preliminary current increase reduces the total calibration time significantly, while the subsequent controlled sweep ensures accuracy. The system performs the time-consuming precise measurement only over the necessary current range, improving work efficiency without sacrificing calibration quality.
3Productivity
If the sweep starting current value is set to reduce calibration time, then work efficiency improves, but the sweep time to reach valve opening position current value becomes inconsistent across different valves, hindering work standardization
Solution Approach 1:
The patent applies dynamics by making the sweep starting current value adaptive rather than fixed. The system dynamically determines the appropriate starting current value for each valve based on its specific characteristics, allowing the calibration process to be optimized for each individual valve. This dynamic adjustment ensures that all valves are calibrated under consistent time conditions, achieving both high work efficiency and standardized work conditions through automated, valve-specific parameter optimization.
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 approach standardizes the calibration process, improves work efficiency, and enhances accuracy by ensuring consistent sweep times across different valves.
Implementation Method 1
an electromagnetic proportional valve configured to output a pilot pressure to the control valve to actuate the control valve is an electrical actuator, an electrical current is applied to the electromagnetic proportional valve
Implementation Method 2
a pressure measuring means for measuring a pressure change on the inlet side or outlet side of the valve during the electrical current application to the electrical actuator
Data Source
AI summary
To achieve improvement in work efficiency of calibration work and improvement in calibration accuracy, by performing control so that the time taken to increase the sweep of an applied current becomes substantially constant, upon the calibration of a valve opening position current value when a valve operated by electrical current applied to an electrical actuator opens a flow passage. There is provided a predicted value calculating means for predicting a calibration value of a valve opening position current value on the basis of information concerning valve opening position current values, and the sweep starting current value is set so that the time taken to increase the sweep to a predicted value predicted by the predicted value calculating means from a sweep start becomes a fixed time.