Variable-Speed Hydraulic Pump Control for Emergency Shut-Off
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Solution Overview
Problem
Conventional hydraulic machine control systems face challenges in meeting actuating time requirements, emergency closing properties, and suitability for large hydraulic cylinder volumes, particularly in the event of pump failure, while also being energy inefficient and costly.
Innovation Solution
The apparatus employs variable speed hydraulic fixed displacement pumps, a collecting and equalizing tank, a pump assembly with reversible pumps, and a variable speed pump drive, along with an emergency shut-off system and check valves, to ensure efficient energy use, ease of maintenance, and reduced costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If conventional pressure oil sources (reservoirs with pumps) are used, then the system can maintain required working pressure, but energy efficiency deteriorates and acquisition/operating costs increase
Solution Approach 1:
The patent applies dynamics by replacing static reservoir-based pressure systems with dynamic variable-speed pumps that adjust their operation based on real-time hydraulic machine demands. The control unit modulates pump speed to match actual flow requirements, eliminating continuous operation at fixed speeds and reducing energy waste during partial load conditions.
Solution Approach 2:
The patent implements parameter changes by varying the rotational speed of the pumps as a controllable parameter. Instead of maintaining constant pressure through continuous pump operation, the system changes the speed parameter dynamically based on hydraulic machine needs, optimizing energy consumption across different operating conditions.
2Use of energy by stationary object
If variable-speed hydraulic fixed displacement pumps are used, then energy efficiency improves, but actuating time requirements and emergency closing properties may deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-positioning the emergency closing valve and maintaining it in a ready state with pre-charged hydraulic lines. The system prepares emergency response pathways in advance, ensuring that when an emergency occurs, the closing action can be executed immediately without waiting for pump response or system pressurization.
Solution Approach 2:
The patent uses an intermediary emergency closing valve that operates independently of the variable-speed pumps. This intermediary component provides a dedicated emergency response pathway that bypasses the normal variable-speed control system, ensuring reliable emergency closing functionality regardless of pump speed or operational state.
3Use of energy by stationary object
If variable-speed hydraulic fixed displacement pumps are used, then energy efficiency improves, but suitability for large hydraulic cylinder volumes may deteriorate
Solution Approach 1:
The patent applies dynamics by enabling the pump system to dynamically adjust speed based on the specific actuating requirements of large hydraulic cylinders. The control unit calculates the required flow rate based on cylinder volume and desired actuating speed, then modulates pump speed accordingly, maintaining productivity while optimizing energy use.
Solution Approach 2:
The patent implements universality by designing a variable-speed pump system that can adapt to different hydraulic machine types and cylinder volumes. The same pump system can serve multiple functions and scale to different applications by adjusting speed parameters, making it suitable for both small and large cylinder volumes without sacrificing energy efficiency.
4Ease of repair
If conventional apparatus are used, then basic control function is achieved, but maintenance complexity and operating costs increase
Solution Approach 1:
The patent applies taking out by extracting the pressure generation function from complex reservoir and multi-pump systems and consolidating it into a single variable-speed pump unit. This extraction simplifies the overall system architecture, reducing the number of components that require maintenance while maintaining full control functionality.
Solution Approach 2:
The patent implements merging by combining the functions of multiple conventional components (reservoir, pressure pumps, flow control valves) into an integrated variable-speed pump system with electronic control. This consolidation reduces component count and simplifies maintenance requirements while providing equivalent or superior functionality.
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 configuration enhances energy efficiency, environmental compatibility, and reduces acquisition and operating costs by effectively managing hydraulic fluid flow and reservoir pressure, ensuring reliable operation even in fault conditions.
Implementation Method 1
variable speed pump drive (3)
Implementation Method 2
variable speed hydraulic fixed displacement pumps
Implementation Method 3
two unlockable check valves (81, 82)
Data Source
AI summary
An apparatus for controlling a hydraulic machine, for example a turbine, pump or pump turbine, using variable-speed driven fixed displacement pumps. The apparatus includes a device for carrying out an emergency shut-off that is characterized by low energy consumption and high efficiency while guaranteeing all the operation-relevant and safety-relevant requirements of a hydraulic machine.