Work Vehicle Hydraulic Valve Control Without Compensator Valves
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Solution Overview
Problem
Hydraulic systems in work vehicles often experience excessive energy consumption due to the use of compensator valves, which create unnecessary pressure drops, leading to increased load on the pump and reduced fuel economy.
Innovation Solution
A system with parallel hydraulic loads and adjustable flow control valves, controlled by a computing system that determines and adjusts the pressure and flow rates to minimize pump discharge pressure, eliminating the need for compensator valves by optimizing the operation of flow control valves to achieve maximum flow positions based on input pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If compensator valves are used to maintain predetermined pressure drop across flow control valves, then pressure control is improved, but energy consumption increases and fuel economy deteriorates
Solution Approach 1:
The patent removes compensator valves from the hydraulic system entirely. Instead of using compensator valves to maintain pressure drops, the system uses a pump controller that adjusts pump discharge pressure based on real-time pressure sensor feedback from each hydraulic load, eliminating the need for compensator valves and their associated energy losses.
Solution Approach 2:
The patent implements a feedback control system where pressure sensors monitor the pressure at each hydraulic load, and the pump controller continuously adjusts the pump discharge pressure based on this feedback. This closed-loop control maintains adequate pressure at each load without requiring compensator valves, thereby reducing energy consumption.
2Speed
If compensator valves create pressure drop to control flow, then flow control is maintained, but pump load increases and fuel economy decreases
Solution Approach 1:
The patent extracts and removes compensator valves from the system. Flow control is achieved directly through the pump controller adjusting discharge pressure based on feedback from pressure sensors, eliminating the energy-wasting pressure drops created by compensator valves while maintaining adequate flow control to hydraulic loads.
Solution Approach 2:
The patent dynamically changes the pump discharge pressure parameter based on real-time pressure feedback from hydraulic loads. By adjusting this parameter, the system maintains adequate flow control without the fixed pressure drops imposed by compensator valves, thereby reducing energy losses.
3Stability of the object's composition
If compensator valves are positioned adjacent to each flow control valve, then pressure stability is improved, but device complexity increases
Solution Approach 1:
The patent removes compensator valves from the system. Pressure stability is maintained through the pump controller that uses feedback from pressure sensors to adjust discharge pressure, eliminating the need for additional compensator valves and their associated system complexity.
Solution Approach 2:
The pump controller performs multiple functions: it controls pump discharge pressure, responds to pressure feedback from multiple hydraulic loads, and maintains adequate pressure stability for all loads simultaneously. This multi-functional approach replaces the need for individual compensator valves at each load, reducing overall system complexity.
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 reduces energy consumption and improves fuel economy by minimizing the load on the pump and optimizing hydraulic fluid flow without the need for compensator valves, enhancing the efficiency of work vehicle operations.
Implementation Method 1
a first pressure sensor configured to capture data indicative of a first pressure of the hydraulic fluid being supplied to the first hydraulic load by the first flow control valve. In addition, the work vehicle includes a second pressure sensor configured to capture data indicative of a second pressure of the hydraulic fluid being supplied to the second hydraulic load by the second flow control valve
Implementation Method 2
a first flow control valve defining an adjustable orifice positioned upstream of each hydraulic load that controls the flow rate of the hydraulic fluid being delivered to the corresponding load(s). In this respect, each flow control valve controls the flow rate of the hydraulic fluid being supplied to the downstream load(s) based on the opening position or cross-sectional area of its orifice
Implementation Method 3
a pump configured to supply hydraulic fluid to the first and second hydraulic loads via first and second fluid conduits, respectively
Data Source
AI summary
A work vehicle a computing system configured to receive first and second input associated with controlling the operation of the first and second hydraulic load, respectively. Furthermore, the computing system is configured to control the operation of a first or second flow control valve corresponding to the one of the first or second hydraulic loads associated with the greater hydraulic fluid pressure such that the corresponding adjustable orifice is at a maximum flow position. Additionally, the computing system is configured to determine the first and second pressures of the hydraulic fluid being supplied to the first or second hydraulic loads. Moreover, the computing system is configured to control the operation of the first or second flow control valve corresponding to another of the first or second hydraulic loads based on the corresponding received first or second input and the determined first and second pressures.