2015 Fluid Power Innovation & Research Conference (FPIRC 15) Empirical Method for Determining CB Efficiency and Stability
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1 2015 Fluid Power Innovation & Research Conference (FPIRC 15) Bernd Zähe, Steve Weber, Kevin Cochran, and Dave Herbert 1
2 Counterbalance Valve s for Overrunning (Gravity Assisted) Loads Balance Energy Efficiency And Dynamic Stability Often Efficiency is Compromised at Expense of Stability Limited Counterbalance Valves Commercially Energy Efficiency is Particularly Important for Mobile Equipment Pump & Fuel Tank Size Is Limited 2
3 Typical Load Control Proportional Directional Valves If Load is constant, then Simple Relief Valve Would Suffice But Loads Vary a Lot! So CB Valves Include Pilot Assist Reduces Valve s Relief Setting to Release the Load Note: Heavy Loads Require Less Pilot Assist than Light Loads to Release / Lower Self -Pilot External -Pilot 3
4 4
5 Current Art Typical Counterbalance Valves Screw-in Cartridge Style CB Valve Schematic Symbol Specialized Relief Valve Includes Free Flow Check Valve for Efficient Load Advance CB Settings ~ 130% of Max Anticipated Load Pressure Assures Valve Fully Closes Despite Hysteresis Prevents Nuisance Openings (due to Minor Pressure Spikes) Return Line Backpressure for Controlled Load Deceleration 5
6 Current Art Typical Counterbalance Valves (Net Pilot Area) PILOT RATIO = (Net Load Area) Specialized Relief Valve (A3 - A2) PILOT RATIO = (A2 - A1) Pilot Assist Reduces CB Valve Relief Setting Pilot Ratio Geometric Area Ratio Determines how much Prelief is reduced per unit pilot pressure Example: If PR = 10, 1 bar Ppilot reduces Prelief by 10 bar 6
7 Current Art Typical Counterbalance Valves Fspring P3 (A3 - A2) PILOT RATIO = (A2 - A1) Specialized Relief Valve Valve Relief Setting = Fspring (P3 PR) Where Valve Setting = pressure required to open the valve at Port 1 Fspring = Spring Pre-Load, mechanical spring force holding the valve closed P3 = Pilot Pressure, hydraulic pressure applied at Port 3 PR = Pilot Ratio, geometric ratio between the valve s load port area and pilot port area 7
8 Current Art Typical Counterbalance Valves (A3 - A2) PILOT RATIO = (A2 - A1) Specialized Relief Valve Generally speaking High Pilot Ratios = Less pressure energy required to release load Low Pilot Ratios = More energy required but more stable load motion 8
9 By Definition Pilot Ratio = Ratio of Internal Geometric Areas But we can also measure PR experimentally Flow Limited to 20 lpm Gradually Increase Ppilot Measure Pload v- Ppilot 9
10 Load Pressure v- Pilot Pressure FPIRC 15 Load Released or Lowered Line Slope ~ Pilot Ratio Spring Force Holding Load 10
11 Load Pressure v- Pilot Pressure FPIRC 15 Low PR More Stable High PR More Efficient 11
12 Load Pressure v- Pilot Pressure FPIRC 15 Potential Power Saved by Increasing Pilot Ratio for 1.5:1 to 10:1 Challenge: Select Proper Pilot Ratio to Optimize Stability and Energy Efficiency 12
13 Force Balance on a Cylinder FPIRC 15 F P3 x A CR F + Ppilot A CR = Pload A P1 x A Where F = the mechanical load force Ppilot = pilot pressure (P3) A = cylinder piston area (cap end) CR = cylinder ratio = piston area / rod area Pload = hydraulic pressure load (P1) 13
14 Force Balance on a Cylinder F + Ppilot A CR = Pload A P3 is additive to load pressure (P1) by factor of 0.5 if the cylinder ratio = 2 2 if the cylinder ratio = 0.5 Neglects friction FPIRC 15 Force Balance Lines Where the Cylinder Just begins to Move Cylinder Ratio = 0.5 Load Load Cylinder Ratio = 2 14
15 Force Balance on a Cylinder Point A Cylinder Motion Initiated for 1.5:1 CB Valve (CR = 2) Point B Cylinder Motion Initiated for 10:1 CB Valve (CR = 2) 15
16 Regions of Cylinder Motion and Stability Region A: Cylinder is Not Yet Moving (Inherently Stable) Region C: Typical for No Gravity Assist (Inherently Stable) Region B: Typical for High Overrunning Loads (Potentially Unstable) Challenge: Select Proper Pilot Ratio to Optimize Stability and Energy Efficiency 16
17 Load Pressure v- Pilot Various Flow Rates FPIRC 15 Typical Counterbalance Valve ~3:1 Pilot Ratio Constant Slope Pilot Ratio 17
18 Load Pressure v- Pilot Various Flow Rates FPIRC 15 Triple Pilot Ratio Counterbalance Pilot Ratio ~ 5:1 Pilot Ratio ~ 2:1 Pilot Ratio ~ 5:1 18
19 Load Pressure v- Pilot Various Flow Rates FPIRC 15 Load Motion Condition Start Load in Motion Load At Max Speed P3 Pilot Pressure Required Standard 3:1 CB Valve Triple Pilot Ratio CB Valve Approx. Triple Pilot Ratio Energy Savings 4 L/min 19 bar 15 bar 21% 60 L/min 35 bar 20 bar 43% 4 L/min 75 bar 55 bar 27% 60 L/min 110 bar 80 bar 27% 19
20 Valve Construction Comparison FPIRC 15 20
21 Test Example Typical 3:1 CB Valve Triple Ratio CB Valve 21
22 Test Example CB Valve Relief Setting 70 bar 280 bar CB Valve Flow P1 / P3 Pressure Standard 3:1 CB Valve Triple Pilot Ratio CB Valve Approx. Triple Pilot Ratio Energy Savings 0 L/min 20 bar 15 bar 25% 60 L/min 65 bar 55 bar 15% 0 L/min 70 bar 60 bar 14% 60 L/min 115 bar 85 bar 26% 22
23 Comparison using a 2:1 cylinder ratio and 3:1 counterbalance Cylinder (CR=2.0) retracts without outer forces (600 mm stroke) Different counterbalance valves on piston side P inlet vs Q across counterbalance CBCA 210 bar opens at (60 * 3)+30 bar 23
24 Comparison using a 2:1 cylinder ratio and 3:1 counterbalance Cylinder (CR=0,5) extends with no outer forces (600 mm stroke) Different counterbalance valves on rod end side P rod end vs Q across counterbalance CBCA 210 bar opens at (42*3)+84 bar = 210 bar 24
25 Thank You 25
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