Leakage modulation in hydraulic systems containing a three-way spool valve

Abstract

Hydraulic systems and associated methods configured to reduce leakage past a spool valve when the system is in a neutral state. Leakage reduction is achieved by shifting the spool valve within the spool bore. The amount of shifting can be controlled by a pressure controller that sets one or pressures in the system and actively/dynamically adjusts the system to achieve a desired pressure or set of pressures by shifting the spool valve.

Claims

1. A hydraulic system having an operational state and a neutral state and comprising: a fluid supply line having a supply port and in fluid communication with a work port, the work port being in fluid communication with a tank line having a tank port and being connected to a tank; a spool valve having a spool at least partially disposed in a spool bore defining an axis, the spool being axially moveable within the bore and being adapted to regulate fluid flow from the supply line to the work port and from the work port to the tank; a driver; and a pressure controller adapted to receive one or more pressure inputs including at least a sensed pressure at either the supply port or the tank port that is blocked by the spool and provide one or more flow outputs based at least in part on the one or more pressure inputs, the one or more flow outputs causing the driver to axially shift the spool from a neutral position within the bore to an axially shifted neutral position within the bore when the system is in the neutral state.

2. The hydraulic system as in claim 1, wherein the one or more pressure inputs include at least one sensed pressure at a location in the system, and at least one pre-determined pressure demand for the location.

3. The hydraulic system as in claim 1, wherein the one or more flow outputs cause the driver to axially shift the spool to an axially shifted neutral position such that the supply port is at least partially opened to a flow passage defined by the spool to provide direct fluid communication between the supply port and the work port.

4. The hydraulic system as in claim 1, wherein the one or more flow outputs cause the driver to axially shift the spool to an axially shifted neutral position such that the tank port is at least partially opened to a flow passage defined by the spool to provide direct fluid communication between the work port and the tank port.

5. The hydraulic system as in claim 1, wherein the one or more flow outputs cause the driver to axially shift the spool to increase an axial deadband distance of the spool associated with the supply port or to increase an axial deadband distance of the spool associated with the tank port, without opening either of the supply port or the tank port to a flow passage defined by the spool.

6. The hydraulic system of claim 1, further comprising one or more pressure sensors that detect one or more fluid pressures within the system and provide measurements of the one or more fluid pressures to the pressure controller as one or more of the one or more pressure inputs.

7. The hydraulic system of claim 1, wherein the pressure controller is configured to command the driver to axially shift the spool within the bore when the system is in the neutral state before a pressure at the work port reaches a level high enough or low enough to cause drifting of a cylinder connected to the work port.

8. The hydraulic system of claim 1, wherein a pre-determined flow limit limits a distance that the spool shifts axially in response to the one or more flow outputs.

9. The hydraulic system of claim 1, wherein the axial shifting of the spool is determined by a flow map that calculates an optimal position of the spool relative to the bore based at least in part on one of the one or more pressure inputs.

10. The hydraulic system of claim 1, wherein the driver comprises a solenoid, or wherein the spool is a main stage spool and the driver comprises a voice coil and a pilot spool.

11. The hydraulic system as in claim 10, wherein the solenoid is a proportional solenoid adapted to apply force to the spool in proportion to a current supplied to the proportional solenoid.

12. The hydraulic system of claim 1, wherein the spool comprises first and second lands, each of the lands having an associated deadband distance with an associated port, and wherein the axial shifting causes one of the deadband distances to increase and the other deadband distance to decrease.

13. A three-way spool valve comprising: a valve body defining a valve bore that extends along an axis, the valve body also including a supply port, a work port and a tank port all in fluid communication with the valve bore; a spool positioned within the bore, the spool including a first land axially separated from a second land by a flow passage, the spool being axially moveable along the axis when the spool valve is in a neutral state, wherein the spool is adapted to be axially shifted by a driver, when the spool valve is in the neutral state, in response to a command from a pressure controller that receives one or more pressure inputs including at least a sensed pressure at either the supply port or the tank port that is blocked by the spool and provides one or more flow outputs based at least in part on the one or more pressure inputs.

14. The three-way spool valve as in claim 13, wherein the one or more pressure inputs include at least one sensed pressure at a location in the valve, and at least one pre-determined pressure demand for the location.

15. The three-way spool valve of claim 13, wherein at least one of the one or more flow outputs causes the spool, when the spool valve is in the neutral state, to shift such that the first land at least partially opens the supply port to the flow passage.

16. The three-way spool valve of claim 13, wherein at least one of the one or more flow outputs causes the spool, when the spool valve is in the neutral state, to shift such that the second land at least partially opens the tank port to the flow passage.

17. The three-way spool valve of claim 13, wherein at least one of the one or more flow outputs causes the spool, when the spool valve is in the neutral state, to shift such that the first land moves towards the tank port and a deadband distance associated with the second land decreases but the tank port remains blocked to the flow passage by the second land.

18. The three-way spool valve of claim 13, wherein at least one of the one or more flow outputs causes the spool, when the spool valve is in the neutral state, to shift such that the second land moves towards the supply port and a deadband distance associated with the first land decreases but the supply port remains blocked to the flow passage by the first land.

19. The three-way spool valve of claim 14, wherein the spool is axially shifted when the spool valve is in the neutral state according to, at least in part, a flow map that calculates an optimal position of the spool based at least in part on the pre-determined pressure demand.

20. The three-way spool valve of claim 13, wherein a pre-determined flow limit limits a distance that the spool shifts axially in response to the one or more flow outputs.

21. The three-way spool valve of claim 13, wherein the driver comprises a solenoid, or wherein the spool is a main stage spool and the driver comprises a voice coil and a pilot spool.

22. The three-way spool valve as in claim 21, wherein the solenoid is a proportional solenoid adapted to apply force to the spool in proportion to a current supplied to the proportional solenoid.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic illustration of a prior art hydraulic system including a three-way spool valve, the hydraulic system being in a neutral state.

(2) FIG. 2 is a schematic illustration of an example hydraulic system including a three-way spool valve in accordance with the present disclosure, the hydraulic system being in a neutral state and the spool valve being in a position in which the tank line/tank port is partially open to the work port.

(3) FIG. 3 is a schematic illustration of an example feedback loop flow control in accordance with the systems and methods of the present disclosure.

DETAILED DESCRIPTION

(4) Various embodiments will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments does not limit the scope of the claims attached hereto. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments for the appended claims.

(5) Referring to FIG. 1, a prior art hydraulic system 100 in a neutral state includes a fluid supply 101 (e.g., a pump) that supplies hydraulic fluid via a supply line 102 through a supply port 105 to a work port 104. The work port 104 is connected to an actuator 106, (e.g., a cylinder), that drives a load. Fluid from the work port empties to the tank 108 via a tank port 107 and tank line 110.

(6) A three-way spool valve includes a spool 112 disposed in a spool bore 114 that defines an axis A.

(7) One or more drivers 116 axially drive(s) the spool 112 to move axially (i.e., in either direction along the axis A) within the spool bore 114. The one or more drivers can be, e.g., one or more solenoids and can be connected to a power source 118 and/or one or more controllers 120 for controlling when the driver(s) 116 are actuated and/or how much to actuate the driver(s) 116.

(8) The spool 112 includes a first or supply side land 122 and a second or tank side land 124. The first and second lands are connected by a shaft 126. The lands and shaft form a rigid structure and move axially within the bore in unison. An axial flow passage 109 is defined between the lands 122 and 124 and, more specifically, between the edge 123 of the supply side land 122 and edge 125 of the tank side land 124.

(9) The spool 112 regulates fluid flow from the supply line/supply port to the work port, and from the work port to the tank line/tank port. In FIG. 1, the hydraulic system 100 is in a neutral state, the supply side land 122 is blocking the supply port 105, and the tank side land 124 is blocking the tank port 107. That is, the edge 123 of the supply side land 122 coincides (transversely to the axis) with a region 130 of the spool bore 114 between the supply port 105 and the work port 104; and the edge 125 of the tank side land 124 coincides (transversely to the axis) with a region 132 of the spool bore 114 between the tank port 107 and the work port 104.

(10) As mentioned, the hydraulic system 100 is in a neutral state. In this neutral state, the spool 112 is in a neutral (and centered) position within the spool bore 114 and with respect to the supply line 102 and the tank line 110. In the centered position of the spool 112 as shown, the deadband distance B1 of the supply side land 122 is equal to, or at least approximately equal to, the deadband distance B2 of the tank side land 124. Thus, in this example, the supply side and tank side lands are the same or approximately the same size, at least along the axial dimension.

(11) Fluid leakage Q.sub.leak, supply in units of volume per time from the supply 101 past the deadband distance B1 of the supply side land 122 into the flow passage 109 when the supply side land 122 is blocking the supply port 105 can be governed by the following equation (1), in which D is the diameter (perpendicular to the axis A) of the supply side land 122, c is the clearance between the supply side land 122 and the wall 115 of the bore 114, P.sub.s is the fluid pressure in the supply line 102, P.sub.port is the fluid pressure at the work port (which is partially a function of the load), x.sub.supply is the leakage distance (measured along an axial direction) past the supply side land 122, which also corresponds to the deadband distance B1, and is the viscosity of the hydraulic fluid:

(12) $\begin{array}{cc}{Q}_{\mathrm{leak},\mathrm{supply}}=\frac{D{c}^3\left(P_s-P_{\mathrm{port}}\right)}{x_{\mathrm{supply}}}& \left(1\right)\end{array}$

(13) Fluid leakage Q.sub.leak, tank in units of volume per second from the work port 104 past the deadband distance B2 of the tank side land 124 into the flow passage 109 when the tank side land 124 is blocking the tank port 107 can be governed by the following equation (2), in which D is the diameter (perpendicular to the axis A) of the tank side land 124, c is the clearance between the tank side land 124 and the wall 115 of the bore 114, P.sub.tank is the fluid pressure in the tank line 110, P.sub.port is the fluid pressure at the work port (which is partially a function of the load), x.sub.tank is the leakage distance (measured along an axial direction) past the tank side land 124, which also corresponds to the deadband distance B2, and is the viscosity of the hydraulic fluid:

(14) $\begin{array}{cc}{Q}_{\mathrm{leak},\mathrm{tank}}=\frac{D{c}^3\left(P_{\mathrm{port}}-P_{\mathrm{tank}}\right)}{x_{\mathrm{tank}}}& \left(2\right)\end{array}$

(15) In both equations (1) and (2), leakage is inversely proportional to leakage distance.

(16) In the hydraulic system 100, which is in a neutral state, the spool 112 is automatically positioned/returned to the neutral (and centered) position shown and described above, regardless of any differential P1 between P.sub.s and P.sub.port and regardless of any differential P2 between P.sub.port and P.sub.tank. Thus, due to the leakage distances provided by the depicted configuration, the hydraulic system 100 can suffer from unwanted leakage, for example, from the supply 101 to the work port 104 in the event of a positive P1 that induces flow from the supply 101 to the work port 104, as well as leakage from the work port 104 to the tank line 110 in the event of a positive P2 that induces flow from the work port 104 to the tank line 110.

(17) Referring now to FIG. 2, a hydraulic system 200 in accordance with the present disclosure and configured to reduce unwanted leakage past the spool valve is schematically illustrated in a neutral state. Many of the features of the system 200 are equivalent to features of the system 100, and are indicated with like reference numbers.

(18) The system 200 is designed to actively control pressure within the system 200 to reduce undesirable drifting of the cylinder 106 when the system 200 is in the neutral state.

(19) One or more pressure sensors 206 actively measure the pressure at one or more locations within the system 200, such as the supply line 102/the supply port 105, the work port 104, and tank line 110/tank port 107. The measured pressure(s) are fed as inputs to the pressure controller 210. The pressure controller 210 can include and/or work in conjunction with, a computer processor that executes instructions stored on a non-transitory computer-readable medium.

(20) The pressure controller 210 thus receives pressure inputs and also outputs flow commands to the system 200 as part of a feedback loop described in more detail below in connection with FIG. 3. The pressure inputs can also include one or more pre-determined pressure demands for one or more locations within the system 200.

(21) In some examples, a given flow command is at least partially based on the input(s) received by the controller 210 and a predefined pressure demand. For example, based on pressure readings at the supply line 102/supply port 105, the work port 104, and/or the tank line 110/tank port 107 as compared with one or more predefined pressure demand input(s), the pressure controller 210 can output a command to the one or more drivers 116 (or to a controller 120 that controls the one or more drivers 116) to axially shift the spool 112 in order to achieve or at least approach the predefined pressure demand, e.g., at the work port 104 or the supply port 105, taking into account one or more other constraints imposed by the controller 210, such as a predefined flow limit.

(22) In the example shown in FIG. 2, the pressure controller 210 has provided a command to shift the spool 112 such that the tank line 110/tank port 107 is partially opened to the flow passage 109, allowing direct flow between the work port 104 and the tank port 107 that is at least partially determined by the size of the opening 211. Thus, excess pressure in the work port 104, which might otherwise cause drifting of the cylinder 106, is relieved or partially relieved by allowing limited flow into the tank 108 via the controlled opening 211.

(23) It should be appreciated that the position of the spool 112 in FIG. 2 is just one example of a spool shifting from the neutral position shown in FIG. 1 that can be demanded by the pressure controller 210 while the system 200 is in the neutral state.

(24) In further non-limiting examples, the pressure controller 210, in response to at least one or more received pressure inputs, causes the one or more drivers 116 to actuate axial movement of the spool 112 such that the opening between the tank port 107 and the flow passage 109 is larger or smaller than the opening 211.

(25) In further non-limiting examples, the pressure controller 210, in response to at least one or more received pressure inputs, causes the one or more drivers 116 to actuate axial movement of the spool 112 such that the supply side land 122 shifts towards the tank port 107 without unblocking the tank port 107 by the tank side land 124. Thus, in these examples, the shifting of the spool 112 (compared to the position in FIG. 1) increases the deadband distance of the supply side land 122 and decreases the deadband distance of the tank side land 124, while maintaining transverse coincidence of the edge 204 (corresponding to the edge 125 in FIG. 1) of the tank side land 124 with the axial region 132 of the spool bore 114 between the tank port 107 and the work port 104. The precise magnitude of axial shifting of the spool can be determined, at least in part, by a predefined pressure demand at, e.g., the work port 104.

(26) In further non-limiting examples, the pressure controller 210, in response to at least one or more received pressure inputs, causes the one or more drivers 116 to actuate axial movement of the spool 112 such that an opening of an appropriate size is formed between the supply port 105 and the flow passage 109.

(27) In still further non-limiting examples, the pressure controller 210, in response to at least one or more received pressure inputs, causes the one or more drivers 116 to actuate axial movement of the spool 112 such that the tank side land 124 shifts towards the supply port 105 without unblocking the supply port 105 by the supply side land 122. Thus, in these examples, the shifting of the spool 112 to a shifted neutral position (compared to the neutral position in FIG. 1) increases the deadband distance of the tank side land 124 and decreases the deadband distance of the supply side land 122, while maintaining transverse coincidence of the edge 203 (corresponding to the edge 123 in FIG. 1) of the supply side land 122 with the axial region 130 of the spool bore 114 between the supply port 105 and the work port 104. The precise magnitude of axial shifting of the spool can be determined, at least in part, by a pressure demand at, e.g., the supply port 105.

(28) The pressure controller 210 can be adapted to actively (e.g., continuously, or repeatedly) monitor pressures in the system 200 and thereby actively provide commands to the spool valve driver(s), even as characteristics of the system may change while it remains in neutral, e.g., if a load on the cylinder 106 increases or decreases while the system 200 remains in neutral.

(29) The commands provided by the pressure controller 210 may be calibrated according to one or more algorithms or flow maps that can be, e.g., pre-programmed into the system 200. For example, based on the leakage equations provided above, and in situations in which the supply line pressure is measured to be lower than the work port pressure, an optimal axial shifting (x.sub.offset, optimal) of the spool 112 to a shifted neutral position relative to its neutral position (FIG. 1) that optimizes the total leakage of the system 200 in the neutral state to minimize undesirable drift of the cylinder 106 can be calculated with the following equation (3):

(30) $\begin{array}{cc}{x}_{\mathrm{offset},\mathrm{optimal}}=\frac{\sqrt{P_{\mathrm{port}}-P_{\mathrm{tank}}}{x}_{\mathrm{supply}}-\sqrt{P_{\mathrm{port}}-P_{\mathrm{supply}}}{x}_{\mathrm{tank}}}{\sqrt{P_{\mathrm{port}}-P_{\mathrm{supply}}}+\sqrt{P_{\mathrm{port}}-P_{\mathrm{tank}}}}& \left(3\right)\end{array}$

(31) It should be appreciated that the calculation of x.sub.offset, optimal using the above equation (3) can be performed actively as pressure readings at the supply, the work port, and the tank are actively updated (i.e., through a continuous feedback loop) and fed to the controller 210, thereby providing for a dynamic system that responds quickly to pressure changes in the neutral state and compensates for those pressure changes by making adjustments to the spool position according to active calculations of x.sub.offset, optimal.

(32) Referring now to FIG. 3, a schematic illustration of an example flow control 300 in accordance with the systems and methods of the present disclosure is shown.

(33) In the flow control 300, the pressure controller 210 receives an actual pressure measurement input from the work port, P.sub.workport, and a predefined pressure demand (i.e., predefined target) P.sub.demand for the work port. The predefined pressure P.sub.demand can be calculated, at least partially, to minimize drift of the cylinder 106 (FIG. 1) under at least certain conditions.

(34) The work port pressure is monitored to make sure the actual sensed pressure (P.sub.workport) is equal to P.sub.demand, or within a given predefined deviation from P.sub.demand.

(35) If there is no discrepancy between P.sub.workport and P.sub.demand or the magnitude of the discrepancy is less than a predefined deviation, then no corrective action is taken by the pressure controller 210, i.e., the axial position of the spool is not changed.

(36) If there is a discrepancy between P.sub.workport and P.sub.demand or the discrepancy meets or exceeds the predefined deviation (e.g., because of leakage across the valve from the supply port to the work port), the pressure controller 210 issues a flow command Q.sub.demand. Q.sub.demand can be calculated by the pressure controller, accessed from a look-up table, etc. Q.sub.demand sets a flow from the work port to the tank port which would effectively correct the detected over-pressurization of the work port and equalize P.sub.workport with P.sub.demand or at least bring them to within the predefined deviation.

(37) In some examples, the value of the determined Q.sub.demand is checked against a pre-determined flow limit 310 (a maximum value that ensures effective control is maintained by the system). If the determined Q.sub.demand is greater than the flow limit, then the final Q.sub.demand is set to the flow limit. If the determined Q.sub.demand is lower than the flow limit, then the determined Q.sub.demand is used as the final Q.sub.demand.

(38) Based on the value of the final Q.sub.demand, the desired spool position required to achieve the final Q.sub.demand (e.g., by accessing data from a flow map 312) is determined, and a spool shifting command x.sub.demand is sent to the spool 112, e.g., via the one or more drivers 116 and/or the one or more controllers 120 (FIG. 2), which axially shifts the spool 112 according to the spool shifting command to the calculated spool position. In the case where the valve is a proportional valve and the spool driver is a proportional solenoid, a current value suitable for moving the spool to the desired spool position (e.g., as determined by the flow map or other means) is applied to the proportional solenoid. In the case of a voice coil, the voice coil controls a pilot spool, which provides the needed flow/pressure to move the main stage spool 112, the current to the voice coil being proportional to the flow provided to move the main stage spool 112.

(39) Once the spool position has been adjusted by the spool driver, the system loops back and the newly sensed P.sub.workport is compared against P.sub.demand. The cycle is preferably repeated in an endless feedback loop to ensure minimal deviation of P.sub.workport from P.sub.demand.

(40) In other flow control examples, a similar feedback loop can be used to make corrections for sensed drops in P.sub.workport caused by leakage from the work port to the tank port. In this alternative feedback loop, Q.sub.demand would correspond to a flow from the supply port to the work port determined to raise the P.sub.workport back to P.sub.demand.

(41) The various embodiments described above are provided by way of illustration only and should not be construed to limit the claims attached hereto. Those skilled in the art will readily recognize various modifications and changes that may be made without following the example embodiments and applications illustrated and described herein, and without departing from the true spirit and scope of the following claims.