WO2012143938A2

WO2012143938A2 - Energy conserving system for a hydraulic machine

Info

Publication number: WO2012143938A2
Application number: PCT/IN2012/000247
Authority: WO
Inventors: Piyush A. MEHTA; Pappu Ruf MOLIA
Original assignee: Mehta Piyush A; Molia Pappu Ruf
Priority date: 2011-04-11
Filing date: 2012-04-09
Publication date: 2012-10-26
Also published as: WO2012143938A3; WO2012143938A8

Abstract

An energy conserving system for a hydraulic machine comprising a reservoir for providing a hydraulic fluid; a motor; a pump; an actuator comprising a motor shaft extending along an axis from a motor; a pump shaft extending along an axis from at least one pump; at least two gear wheels operably connected to each other, wherein a first gear wheel is detachably connected to the motor shaft and a second gear wheel is detachably connected to the pump shaft; the at least one pump coupled to the actuator and the reservoir; wherein the actuator is drivably coupled to the motor for controlling the hydraulic fluid intake of the pump; a master valve in fluid communication with the pump for regulating the flow of the hydraulic fluid; and, a valve plate in fluid communication with the master valve.

Description

^• BACKGROUND OF Tli ; LWENTION

FIELD OF THE I VENTION The present invention relates to a Hydro-E.'ectronic-Mechanical energy saving system for a hydraulic machine in which the energy consumed is conserved and at the same time, the working of the machine is made faster.

BACKGROUND AND PRIOR ART

Energy conserving systems in association with hydraulic machines have been known. Most of these energy conserving systems include varying the number of pumps, generating dynamic operating signals to the hydraulic circuit, use of variable speed motors, so on and sc forth. One such system is disclosed in US449365, which discloses a lift, tilt and steering control system wherein multiple pumps are used for conserving energy in a hydraulic machine.

In another patent EP961035, a hydraulically operated machine, typically a plastic injection moulding machine is disclosed. To save energy, the motor in the system receives its supply via a variable speed controller which is controlled by a dynamic signal derived from the hydraulic circuit. However, the energy saving process of this invention affects the performance of the machine. Also, there is energy saving only at the time of two elements of the machine i.e. during clamping and injection. Hence, need exists for an energy saver system which reduces the overall energy requirement, optimizes the energy consumption and also improves the performance of the machine.

SUMMARY The present invention is directed to an energy conserving system for a hydraulic machine comprising a reservoir for providing a hydraulic fluid; a motor; a pump; an actuator comprising a motor shaft extending along an axis from a motor; a pump shaft extending along an axis from at least one pump; at least two gear wheels operably connected to each other, wherein a first gear wheel is detachably connected to the motor shaft and a second gear wheel is detachably connected to the pump shaft; the at least one pump coupled to the actuator and the reservoir; wherein the actuator is drivabiy coupled to the motor for controlling the hydraulic ^' fluid intake of the pump; a master valve in fluid communication with the pump for regulating the flow of the hydraulic fluid; and, _, a valve plate in fluid communication with the master valve.

According to a preferred embodiment, the invention is directed to an energy conserving system for an injection molding machine.

Further, the invention relates to a method for energy conservation in a hydraulic device performing at least one function comprising providing hydraulic fluid from a reservoir to at least one pump using an actuator; wherein the actuator comprises a motor shaft extending along an axis from a motor; a pump shaft extending along an axis from the pump; at least two gear wheeic operably connected to each other, wherein a first gear wheel is detachably connected to the motor shaft and a second gear wheel is detachably connected to the pump shaft; transporting the hydraulic fluid from the pump to the master valve; and, transporting the hydraulic fluid from the master valve to the valve plate. BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding, reference should now be made to the embodiments illustrated in greater detail in the accompanying drawings and described below by way of examples. FIG.1 is a block diagram of the energy conserving system according to an embodiment.

FIG. 2 is a block diagram of the energy conserving system according to a preferred embodiment.

It is to be understood that the drawings are not to scale and are schematic in nature. In certain instances, details which are not necessary for an understanding of the present invention or which renders other details difficult to perceive, may be omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein. DETAILED DESCRIPTION

The present invention relates to an energy conserving system for a hydraulic machine. The invention further relates to method for energy conservation in a hydraulic device.

According to an embodiment, the energy conserving system can be used for any hydraulic machine.

According to a preferred embodiment, the energy conserving system can be used for saving energy in an Injection Moulding Machine, Blow Moulding Machine, Bakelite Moulding Machine, Hydraulic Power Press, Hydraulic Sheet Cutting Machine, Hydraulic Bulldozer, Hydraulic Crane, Hydraulic Ram etc.

According to a preferred embodiment, the energy conserving system is used in an injection moulding machine.

According to an embodiment, the invention relates to an energy conserving system for a hydraulic machine comprising a reservoir for providing a hydraulic fluid; a motor; a pump; an actuator comprising a motor shaft extending along an axis from a motor; a pump shaft extending along an axis from at least one ump; at least two gear wheels operably connected to each other, wherein a first gear wheel is detachably connected to the motor shaft and a second gear wheel is detachably connected to the pump shaft; the at least one pump coupled to the actuator and the reservoir; wherein the actuator is drivably coupled to the motor for controlling the hydraulic fluid intake of the pump; a master valve in fluid communication with the pump for regulating the flow of the hydraulic fluid; and, a valve plate in fluid communication with the master valve.

According to a preferred embodiment, the actuator of the energy conserving system comprises two gear wheels. However, more than two gear wheels can be used to facilitate the working of the system.

According to a embodiment, the motor is selected from a fixed displacement motor, fixed speed motor and a variable speed motor. According to a preferred embodiment, the motor is a fixed speed motor.

According to an embodiment as shown in Fig. 1, a reservoir (1 12) provides hydraulic fluid to the energy conserving system (100).

Any hydraulic fluid known to a person skilled in the art can be used in this invention.

The energy conserving system (100) of this invention further comprises an actuator (102) which comprises a motor shaft (106) extending along an axis from a motor (101); a pump shaft (107) extending along an axis from a pump (1 10); two gear wheels (104) wherein a first gear wheel (104) is detachably connected to the motor shaft (106) and a second gear wheel (105) is detachably connected to the pump shaft (107). According to an embodiment, the motor shaft is connected to the motor using coupling means (103). Any coupling means known to a person skilled in the art can be used.

According to a preferred embodiment, the coupling means (103) are well-housing and nylon coupling. However, any other suitable coupling means can be used for this purpose.

According to another embodiment, ball bearings (108) are fixed on the motor shaft (106) and the pump shaft (107) to facilitate the shafts to rotate freely. The first gear wheel (104) is fixed in between the tv/o ball bearings (108) on the motor shaft (106) and the second gear wheel (105) is fixed in between the two ball bearings (108) on the pump shaft (107).

The pump (110) is used to draw hydraulic fluid from the reservoir (112). As the motor (101) starts, the motor shaft (106) rotates which in turn rotates the first gear wheel (104), the second gear wheel (105) and the pump shaft (107). The rotation of both the gear wheels (104 and 105) helps the hydraulic pump (110), which is connected to the pump shaft (107) to draw hydraulic fluid from the reservoir (112) through input line (111). A filter (1 14) is used to prevent any unwanted particles from the hydraulic fluid to enter the pump (110). According to another embodiment, the energy conserving system further comprises at least one flow control valve selected from needle valves, gate valves, ball valves, check valves and butterfly valves. According to a preferred embodiment, the flow control valve is a needle valve.

A first needle valve (1 13) is fixed in between the reservoir (1 12) and the pump (1 10) to regulate the flow of the hydraulic fluid. According to yet another embodiment, the flow of the hydraulic fluid from the reservoir to the pump is controlled using a first needle valve (113). Through an output pipe (109), this hydraulic fluid is transported from the pump (110) to the P-port of the master valve (1 5). From the T-port (1 17) of the master valve (115), excess fluid is bypassed to the reservoir (1 12). From the master valve (1 15), tne hydraulic fluid is transported to the valve plate (120).

According to another embodiment, the energy conserving system further comprises at least one nonreturn valve.

According to an embodiment, the energy conserving system further comprises one non-return valve.

A first non-return valve (118) is positioned upstream of the valve plate (120) to prevent back-flow of the hydraulic fluid.

According to an embodiment, a conventional valve plate is used for the system. However, any valve plate which performs the function as described herein can be used for the purposes of this invention.

According to an alternate embodiment, the energy conserving system further consists of at least one energy directional valve. According to a preferred embodiment, the energy conserving system consists of one energy directional valve. ' ,: <;rding to another alternate embodiment, the energy system further comprises at least one pressure vessel.

According to a preferred embodiment, the energy system comprises one pressure vessel.

According to yet another alternate embodiment, the energy system further comprises at least one valve block comprising at least two valves.

According to a preferred embodiment, the energy conserving system comprises a valve block comprising two valves.

According to an alternate embodiment, the energy conserving system further comprises at least one flow control valve selected from needle valves, gate valves, ball valves, check valves and butterfly valves.

According to a preferred embodiment, the flow control valve is selected from needle valves.

According to a preferred embodiment, the energy conserving system comprises five needle valves- a first needle valve disposed upstream of the reservoir; a second needle valve disposed upstream of the pressure vessel; a third needle valve disposed downstream of the pressure vessel: and a fourth and fifth needle valve disposed downstream of the valve block.

According to yet another embodiment, the energy conserving system further comprises at least one non-return valve for preventing back-flow of the hydraulic, fluid.

According to a preferred embodiment, the energy conserving system further comprises a first nonreturn valve between the master valve and the valve plate, a second non-return valve between the energy directional valve and the pressure vessel and a third non-return valve between the connector block and the valve plate. According to still another alternate embodiment, the energy conserving system further comprises an electronic circuit in communication with the energy directional valve for controlling the flow of the hydraulic fluid. According to a preferred embodiment, the electronic circuit comprises at least one timer ard at least one contractor.

According to a preferred embodiment, the electronic circuit comprises two timers and two contractors.

According to a preferred embodiment, the energy system for conserving energy is used for an injection moulding machine.

An injection moulding machine performs various functions such as locking, refilling, suck back, ejecting-reverse and forward etc. These and other functions of the injection moulding machine will be apparent to a person skilled in the art.

According to a preferred embodiment as shown in FIG. 2, the energy conserving system comprises at least one energy directional valve (herein after referred to as ED valve) (201), at least one pressure vessel (208), a valve block (210) containing at least two valves and an electronic circuit (230) in addition to the system as shown in FIG. 1.

The hydraulic fluid is transported from the output line (109) of the pump (110) to the P-port (202) of the ED valve (201). When the hydraulic machine carries out a function, hydraulic fluid from the A- port (204) of the energy directional valve (201) is transported to the P-port (1 16) of the master valve (1 15). The electronic circuit (230) is used and made to control the ED valve (201) by setting the time for the fluid to go into the Pressure vessel (208). The timing is set in such a manner that in between two functions of the injection moulding machine, the ED valve transports fluid to the Pressure vessel (208). From the T-port (205) of the ED valve (201), excess hydraulic fluid is bypassed to the reservoir (1 12). According to yet another embodiment, the flow of hydraulic fluid from the ED valve (201) to the pressure vessel (208) is contrclled using a second needle valve (206) and a second non-return valve

(207) . As the output is set tkrough the second needle valve (206), compressed energy develops which creates a pressure that increases the speed of the functions of the injection moulding machine.

According to a further embodiment, the electronic circuit (230) sends an operating signal to the ED valve (201) in between two functions.

According to a still further embodiment, the electronic circuit has two timers- a first timer (234) and a second timer (235) and two contractors- a first contractor (236) and a second contractor (237). From L (238), the main electricity line, current is passed to NC (Normal close) of the second contractor (237). The current is then passed to NC of the first contractor (236). From the NC of the first contractor, this current is passed to the first timer's (234) L (Line) and further to C (Current) of the same timer. From NO (Normal Open) of first timer (234)_; the electricity goes to NC of first contractor (236) and from there it flows to coil (243) of the first Contractor (236). From the coil (243), the electricity farther travels to NC of the second timer (235).

A line (239) coming from the panel of the machine (not shown in the figure) goes to NO of the second contractor (237) and from thereon it goes to NO of the same contractor. From NO of second contractor (237), the electricity line goes to the master valve (1 15). One line (241) goes from NC of Contractor (236) to ED valve (201) which automatically starts the ED valve (201), while the hydraulic machine completes one function.

According to another embodiment, the electronic circuit is placed between the panel of the machine (not shown in the figure) and the master valve (115). Electricity line (240) goes from NO of the contractor (237) to the master valve (115).

According to still another embodiment, the compressed hydraulic fluid from the pressure vessel

(208) is further transported to a valve block (210) comprising at least two vaives.

According to a preferred embodiment, the valve block (210) comprises of two valves. The P-ports (211) and the T-ports (214) of the two valves are made common so that they can be utilized as per the functional need. The hydraulic fluid from the B-ports (212 and 213) is transported to a connector block (217) made to make both the lines from the B-ports common. A fourth needle valve (216) and a fifth needle valve (215) are used to adjust the flow of hydraulic fluid from the B-ports (212 and 213 respectively). From the connector block (217), hydraulic fluid goes to the P-port of the valve plate (120).

According to still another embodiment, a third non-return valve (218) is disposed upstream of the valve plate to prevent back flow of the hydraulic fluid. Example

A 60gram capacity Injection Moulding machine which normally would have a 5HP electric motor with 20 litre hydraulic pump and creates upto 1500PSI main master pressure is chosen, The 201itre hydraulic pump, with 1440 rpm(of the motor) flows 24 litre ENCL068 oil to the machine so thai a 60gram article can be moulded.

According to an exemplary embodiment in accordance with FIG. 2, we have used a 1HP electric motor (101). One 25mm OD shaft (106) is connected with the help of welhousing and nylon cuplinkno.M-E28 (103) to the motor. Ball bearings (108) are fixed at the start and end of the motor shaft (106) and the pum shaft (107) to facilitate the shafts to rotate freely. A first gear wheel (104) is fixed in between the two bali bearings (108) on the motor shaft (106). A second gear wheel (105) is fixed besides the first gear wheel (104) using a pump shaft (107) in such a manner that both the gear wheels (104 and 105) are operably connected to each other. As both the gear wheels rotate, extra energy develops and that helps the 17 Litre hydraulic pump (1 10) to uptake 24 litres oil.

The pump (110) of 17 Litre capacity is connected to the shaft (107) with the help of welhousing and a nylon cuplink (103). The pump's output pipe (109) goes to ED valve (201)'s P-port (202). The pump's input end (111) remains in the Oil Tank (112) with a 25 micron Filter (1 14). A first needle valve (1 13) is fixed in between the oil tank (1 12) and the pump (110).

The master valve (1 15)'s drain line (1 17) goes to the Oil Tank (112). master valve (115)'s P-port (116) is connected with A-port (204) of ED valve (201) from where oil comes in. From the P-pori valve (1 18) is fixed in between the master valve (1 15) and the valve plate (120) to prevent the back- flow of the oil. One line from B-port (203) of the ED valve (201) goes to the Pressure Vessel (208). A second needle valve (206) to adjust the oil flow and a second non return valve (207) which prevents back- flow of the oil is fixed in between the ED valve (202) and the Pressure vessel (208). As the output is set through the second needle valve (206), compressed energy develops which creates a pressure that increases the speed of the functions of the injection moulding machine.

The Pressure Vessel (208) is filled with ENCL068 oil. From the top, the oil goes in the Pressure Vessel and from the bottom, oil is transported to a valve block (210) and in between them, a third needle valve (209) is fixed to adjust the flow of the oil. The valve block (210) is made to connect two 032B2 Hydraulic valves. One valve is for Locking Function and other valve is for Refilling Function of the Moulding machine. The P-ports (21 1) and the T-Ports (214) of both the valves are made common. The oil from the B-ports (212 & 213) goes out and meets into a connector block (217) which is used to make both the lines common. A fourth needle valve (216), a fifth needle valve (215) and are used to regulate the flow of the oil. From the connector block (217), the oil is transported to the P-port of the valve plate (120),

A third Non Return valve (218) is fixed in between the connecter block (217) and the valve plate (120). From the master valve(1 15), T-port(117) goes to the oil tank (112) and from P-port(116) one line goes to the valve plate (120) of the machine and a third non-retum valve (218) is fixed in between them.

One Electronic Circuit having two Timers (234 & 235) and. two Contractors (236 & 237) are fixed in between the machine Panel (not shown in the figure) and the master valve(l 15). By using the energy conserving systen: ibr an injection moulding machine, we could save 80% of power. The system worked well with 1HP motor and 17 litre hydraulic pump instead of a 5HP motor and 20 litre hydraulic pump. Also, the speed of locking and refilling functions increased considerably.

Thus, we are directly saving energy by using a smaller motor. In addition to that, energy consumption has been optimized in the system and the overall performance of the machine is improved.

While the present invention has been described with respect to a number of preferred embodiments, those skilled in the art will appreciate a number of variations and modifications of those embodiments. Thus, it is intended that the appended claims cover all such variations and modifications as fall within the true spirit and scope of the present invention.

Claims

CLAIMS I claim:

1. An energy conserving system for a hydraulic machine comprising:

(a) a reservoir for providing a hydraulic fluid;

(b) a motor;

(c) a pump;

(d) an actuator comprising a motor shaft extending along an axis from a motor; a pump shaft extending along an ..axis from at least one pump; at least two gear wheels operably connected to each other, wherein a first gear wheel is detachably connected to the motor shaft and a second gear wheel is detachably connected to the pump shaft; the at least one pump coupled to the actuator and the reservoir; wherein the actuator is drivably coupled to the motor for controlling the hydraulic fluid intake of the pump;

(e) a master valve in fluid communication with the pump for regulating the flow of the hydraulic fluid; and,

(f) a valve plate in fluid communication with the master valve.

2. The energy conserving system as claimed in claim 1 , further comprising at least one pressure vessel

3. The energy conserving system as claimed in claim 1, further comprising at least one energy directional valve.

4. The energy conserving system as claimed in claim 3, further comprising an electronic circuit in communication with the energy directional valve for controlling the flow of the hydraulic fluid.

5. The energy conserving system as claimed in claim 4, wherein the electronic circuit comprises at least one timer and at least one contractor for transmitting an operating signal to the energy directional valve.

6. The energy conserving system as claimed in claim 5, wherein the electronic circuit comprises at least two timers and at least two contractors.

7. The energy conserving system as claimed in claim 1, further comprising at least one valve block comprising at least two valves.

8. The energy conserving system as claimed in claim 1 , further comprising at least one flow control valve selected from needle valves, gate valves, ball valves, check valves and butterfly valves.

9. The energy conserving system as claimed 8, wherein the flow control valve is selected from needle valves.

10. The energy conserving system as claimed in any one of the preceding claims_; comprising a first needle valve disposed upstream of the reservoir; a second needle valve disposed upstream of the pressure vessel: a third needle valve disposed downstream of the pressure vessel: and a fourth and fifth needle valve disposed downstream of the valve block.

1 1. A method for energy conservation in a hydraulic device performing at least one function, the method comprising:

(a) providing hydraulic fluid from a reservoir to at least one pump using an actuator; wherein the actuator comprises a motor shaft extending along an axis from a motor; a pump shaft extending along an axis from the pump; at least two gear wheels operably connected to each other, wherein a first gear wheel is detachably connected to the motor shaft and a second gear wheel is detachably connected to ihe pump shaft;

(b) transporting the hydraulic fluid from the pump to the master valve; and,

(c) transporting the hydraulic fluid from the master valve to the valve plate.

12. The method as claimed in claim 1 1, step a) further comprising controlling the flow of the hydraulic fluid from the reservoir using a first needle valve.

13. The method A claimed in claim 1 1, wherein step b) optionally comprises transporting the hydraulic fluid from the pump to at least one energy directional valve.

14. The method as claimed in claim 13, wherein step b) further comprises sending an operating signal from an electronic circuit to the energy directional valve at the end of a function to transport the hydraulic fluid from the energy directional valve to the pressure vessel.

15. The method as claimed in claim 14, wherein step b) further comprises controlling the flow of the hydraulic fluid from the energy directional valve to the pressure vessel using a second needle valve.,

16. The method as claimed in claim 15, wherein step b) further comprises compressing the hydraulic fluid in the pressure vessel and transporting compressed hydraulic fluid to the valve block comprising at least two valves wherein P ports of the two valves are connected to each other; whereby the connected P ports receive the compressed hydraulic fluid.

17. The method as claimed in claim 16, wherein step b) farther comprises controlling the flow of the hydraulic fluid from the pressure vessel to the valve block using a third needle valve.

18. The method as claimed in claim 17, wherein step b) further comprises conveying the compressed hydraulic fluid through B ports of the two valves to the valve plate.

19. The method as claimed in claim 18, wherein step b) further comprises combining the compressed hydraulic fluid sent from the B ports of the two valves using a connector block.

20. The method as claimed in claim 19, wherein step b) further comprises controlling the flow of the hydraulic fluid from the B ports of the two valves using a third and forth needle valve.