HYDRAULIC PUMP WITH ELECTRONIC ADJUSTABLE PRESSURE SETTING

A hydraulic pump and a method of operating a double acting hydraulic pump is provided. The method includes retrieving a current operating pressure from memory of a controller, controlling a pump assembly to pump hydraulic fluid from a bladder through one of two work ports to a hydraulic tool at the current operating pressure, and updating the current operating pressure based on input from a user interface.

FIELD

The present disclosure relates generally to hydraulic pumps and systems, and more particularly to systems and methods for a hydraulic pump for use with a hydraulic tool.

BACKGROUND

Hydraulic tools can be used to provide an operator with a mechanical advantage for performing work on a workpiece. For example, a hydraulic tool may be a cutting device having blades for cutting an object into separate parts. As another example, a hydraulic tool may be a crimping device for making crimping connections, thereby conjoining two separate pieces by deforming one or both pieces in a way that causes them to hold together. As yet another example, a hydraulic tool may be a lifting cylinder for lifting a workpiece and/or a pipe bender for bending a workpiece.

In general, a hydraulic tool is coupled to a hydraulic pump, which is operable to pressurize a hydraulic fluid. The hydraulic pump transfers the pressurized hydraulic fluid to a cylinder in the hydraulic tool, and the hydraulic tool uses the pressurized hydraulic fluid from the hydraulic pump to perform the work, e.g., cutting, crimping, lifting, etc. The hydraulic pump, therefore, requires mechanisms to pressurize the hydraulic fluid, maintain the pressure, and release the pressure.

SUMMARY

In some aspects, a hydraulic pump is provided. The hydraulic pump includes a bladder that stores hydraulic fluid and a manifold in fluid communication with the bladder and including a work port. The hydraulic pump also includes a pump assembly that pumps hydraulic fluid from the bladder through the work port, a user interface, and a controller in communication with the user interface and the pump assembly. The controller is configured to store a current operating pressure in memory, update the current operating pressure based on input from the user interface, and control the pump assembly to pump the hydraulic fluid from the bladder through the work port at the current operating pressure.

In another aspect, a method of operating a double acting hydraulic pump including a pump assembly, a bladder, two work ports, a controller, and a user interface is provided. The method includes retrieving a current operating pressure from memory of the controller, controlling the pump assembly to pump hydraulic fluid from the bladder through one of the two work ports to a hydraulic tool at the current operating pressure, and updating the current operating pressure based on input from the user interface.

DETAILED DESCRIPTION

Disclosed embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all of the disclosed embodiments are shown. Indeed, several different embodiments may be provided and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the disclosure to those skilled in the art.

Generally, some embodiments provide a double acting hydraulic pump for use with a hydraulic tool and including an electronic adjustable pressure setting. For example,FIG.1illustrates a hydraulic power tool system100including a hydraulic pump102, according to some embodiments, and a hydraulic tool104. Generally, the hydraulic pump102can be operated to provide a pressurized fluid (e.g., a hydraulic oil) to actuate the hydraulic tool104. For example, as shown inFIG.1, the hydraulic pump102can include a power unit106, a pump assembly108, a manifold110, a bladder112, a switch assembly114, a pressure sensor116, a user interface118, a pump controller120with a processor122and memory124, a first work port126, a second port128, and a removable power source or battery130. The hydraulic pump102can be removably coupled to the hydraulic tool104via fluid supply lines132, such as tubing, extending from the work ports126,128. Furthermore, the hydraulic tool104can include a tool head134and a hydraulic cylinder136.

In operation, the power unit106can be powered by the battery130and controlled by the pump controller120, in response to user input from the user interface118, to drive the pump assembly108. The pump assembly108pumps pressurized fluid from the bladder112through the manifold110, one of the work ports126,128, and one of the fluid supply lines132, to the hydraulic tool104. Within the hydraulic tool104, the pressurized fluid pushes the hydraulic cylinder136, which actuates the tool head134. For example, the tool head134may include a set of jaws (not shown), and the hydraulic cylinder136includes a piston (not shown) that moves one or both jaws toward each other, causing a crimping or cutting operation. In another example, the tool head134includes a movable lift structure (not shown), and the hydraulic cylinder136moves the movable lift structure to change an elevation of a workpiece supported by the movable lift structure. Other examples are possible such as, but not limited to, tool heads134with moveable elements (e.g., a bend die and/or a bend roll) that can move a workpiece relative to a stationary element (e.g., a stationary die and/or a stationary roll) to change a shape of the workpiece.

Once an operation is completed, the pump assembly108can pump pressurized fluid from the bladder112through the manifold110, the other one of the work ports126,128, and the other one of the fluid supply lines132, to the hydraulic tool104, thus pushing the hydraulic cylinder136in another direction to reverse its prior movements. In this manner, the hydraulic pump102is a double action pump. That is, the hydraulic pump102includes two work ports126,128, capable of forcing fluid in two directions and, thus, can provide the hydraulic tool with controlled pushing and pulling forces. However, in some embodiments, the hydraulic pump102can be a single action hydraulic pump102, that is, where fluid is controlled in a single direction. Accordingly, while the concepts are described herein with respect to a double action pump illustrated inFIGS.1-4, they may be equally applied to a single action pump.

FIGS.2-4further illustrate the hydraulic pump102according to some embodiments. As shown inFIGS.2-4, the hydraulic pump102can include the work ports126,128, the power unit106, the pump assembly108, the manifold110(shown in detail inFIG.3), the bladder112, the switch assembly114, and a printed circuit board138(e.g., including the controller120ofFIG.1). Though not shown inFIGS.2-4, the hydraulic pump102can further include a housing that houses at least the power unit106, the pump assembly108, the manifold110, the switch assembly114, the printed circuit board138, and/or all or a portion of the bladder112. The housing can also include a battery terminal configured to receive a battery130, and a user interface118.

In some embodiments, the user interface118can include a display and/or inputs configured to receive feedback from an operator, such as one or more buttons, keypads, dials, triggers, switches, wheels, or the like.FIG.5illustrates an example user interface118including a display140and one or more buttons142, such as at least an “up” button142A and a “down” button142B. In some embodiments, the display140can be separate from physical buttons142. In other embodiments, the display140can incorporate electronic buttons142, and, for example, can be an LCD touch screen. Additionally, in some embodiments, the user interface118can be integrated into the housing of the hydraulic pump102(e.g., on an outer surface of the housing, such that user inputs are provided at the housing). In other embodiments, the user interface118can be a separate element coupled to the housing, and the controller120, via a wired connection or wireless connection (e.g., such that user inputs can be provided remote from the housing). In some embodiments, the housing may include a seat upon which the user interface118can be mounted and/or stored.

Furthermore, referring back toFIG.1, in some embodiments, the hydraulic power tool system100can additionally or alternatively include a remote user interface118A. The remote user interface118A can communicate with the controller120via a wireless or wired connection. In some embodiments, the remote user interface118A can be provided through a software application on a mobile phone, tablet, or computer, thereby providing a display and inputs via the mobile phone, tablet, or computer. Both the user interface118and the remote user interface118A can include similar features, such as similar displays and inputs, thus allowing an operator to view the same display outputs from or provide user input to the user interface118or the remote user interface118A. As such, any reference to the user interface118throughout the disclosure may equally apply to the remote user interface118A unless otherwise noted.

Referring now toFIGS.1,3, and4, the power unit106can include a motor146configured to convert electrical energy to rotational motion in order to operate the pump assembly108. In some embodiments, the power unit106can comprise a variable speed motor146. Further, in some embodiments, the power unit106can comprise a brushless direct current (DC) motor146with a planetary gearset.

The power unit106can be powered by a power source, such as the battery130, as shown inFIG.1. The hydraulic pump102can, therefore, be considered a cordless pump as it is battery operated. In some embodiments, the battery130can be an 18-volt battery. Furthermore, in some embodiments, the battery130can be removable from the hydraulic pump102. For example, as noted above, the hydraulic pump102can include a battery terminal, onto which the battery130can be removably coupled. As a result, the battery130can be removed from the hydraulic pump102and recharged and/or replaced, when necessary. In some embodiments, the hydraulic pump102can additionally or alternatively include a power cord configured to be plugged into a power source, allowing an alternative to battery power.

Furthermore, the power unit106can be controlled by the pump controller120. As such, the pump controller120can be in communication with the motor146. The pump controller120can be implemented using hardware, software, and/or firmware. For example, as shown inFIG.1, the pump controller120can include one or more processors122and memory124, e.g., a non-transitory computer readable memory that stores machine language instructions or other executable instructions. The instructions, when executed by the one or more processors122, can cause the pump controller120to carry out various operations of the hydraulic pump102. For example, the memory124can include instructions that, when executed by the processor(s)122, cause the pump controller120to operate the electric motor146in response to user input from an operator. Such user input can be the operator depressing a button142on the user interface118.

The motor146(or, more generally, the power unit106) can be operated to actuate the pump assembly108in order to pump fluid to the hydraulic tool104at an increasing fluid pressure until reaching a preset operating pressure. For example, as shown inFIGS.1,3, and4, the pump assembly108can include a pump148coupled to the power unit106. The pump148withdraws fluid out of the bladder112and supplies pressurized fluid through the manifold110to a respective work port126,128, as controlled by the switch assembly114.

More specifically, as shown inFIGS.1-4, the bladder112operates as a reservoir for storing hydraulic fluid (e.g., hydraulic oil). The bladder112can store the hydraulic fluid at a low pressure level, such as atmospheric pressure or slightly higher than atmospheric pressure (e.g., about 30 psi to about 70 psi in some embodiments). As noted above, the pump assembly108withdraws fluid from the bladder112and forces pressurized fluid through a fluid supply line132into the hydraulic tool104.

Additionally, the fluid travels through the manifold110between the pump assembly108, the bladder112, and the work ports126,128. The switch assembly114can be coupled to the manifold110to provide automated fluid directional control through the manifold110. That is, the switch assembly114can be controlled by the controller120to change a direction of pressurized fluid flow through the first work port126and the second port128, for example, based on user input through the user interface118.

Furthermore, in some embodiments, an operator can set or adjust an operating pressure of the fluid flowing to the hydraulic tool104. That is, the hydraulic pump104can include an electronic adjustable pressure setting through the user interface118. For example, in some embodiments, the controller120can monitor a fluid pressure exiting the hydraulic pump102, or along another location within hydraulic pump12, via the pressure sensor116. For example, the pressure sensor116can be located at a position within a fluid pathway of the hydraulic fluid to measure a pressure of the hydraulic fluid entering the work ports126,128, exiting the work ports126,128, entering the manifold110, exiting the bladder112, or along another point.

Through such monitoring, the controller120can operate the pump assembly108, one or more valves within the manifold110, and/or the switch assembly114to provide pressurized fluid to a hydraulic tool104up to, but not exceeding, a set operating pressure that is stored in the memory124. That is, the controller120can control the pump assembly108, the switch assembly114, and/or the manifold110to pump the hydraulic fluid from the bladder112through the work port126,128until the current operating pressure is reached. For example, in some embodiments, the controller120can stop the motor146when the set operating pressure is reached, adjust the switch assembly114when the set operating pressure is reached, or perform another action when the set operating pressure is reached. An operator can also update and save a new set operating pressure in the memory124through the user interface118. Additionally, in some embodiments, a plurality of operating pressures can be saved in the memory124and a user can select a set operating pressure from one of the saved operating pressures.

FIG.6illustrates an example method150for adjusting a pump pressure setting according to some embodiments. In some embodiments, the method150ofFIG.6can be executed by the pump controller120(e.g., can be stored in the memory124to be executed by the processor122of the pump controller120). It should also be noted that, while certain steps are illustrated inFIG.6and described below in a particular order, in some embodiments, the steps may be executed in a different order than that shown and described, or more or fewer steps may be executed.

As shown inFIG.6, upon waking at step152, the controller120can obtain from the memory124a current pressure setting at step154. The controller120can display the current pressure setting (e.g., a “displayed pressure setting”) at step156, for example, via the display140of the user interface118(or, as noted above, through the remote user interface118A via a software application on a mobile phone, tablet, or computer in communication with the controller120). The controller120can determine if an operator has pressed an up button142A on the user interface at step158. If so, the controller120determines, at step160, if the displayed pressure setting is a maximum operating pressure. For example, in some embodiments, the hydraulic pump102can have a maximum operating pressure of about 10,500 pounds per square inch (PSI) or about 10,000 PSI, or another pressure. If the displayed pressure setting is the maximum operating pressure, the controller120can provide a message via the display140that the maximum operating pressure has been reached at step162and return to step158. If, at step160, the displayed pressure setting is not equal to the maximum operating pressure, the controller120increases the current pressure setting by1PSI (or another number) at step164and returns to step158.

If, at step158, an operator has not pressed the up button142A, the controller120determines if an operator has pressed the down button142B at step166. If so, the controller120determines, at step168, if the displayed pressure setting is a minimum operating pressure. If the displayed pressure setting is the minimum operating pressure, the controller120provides a message via the display140that the minimum operating pressure has been reached at step170and returns to step158. In some embodiments, the maximum and minimum operation pressures can be preset (e.g., factory-set) pressure settings set within the memory124. If, at step168, the displayed pressure setting is not equal to the minimum operating pressure, the controller120decreases the current pressure setting by1PSI (or another number) at step172and returns to step158.

If, at step166, an operator has not pressed the down button142B, the controller120determines if the current pressure setting is not equal to the displayed pressure setting on the user interface118at step174. For example, such an event would occur if the controller120had increased the current pressure setting at step160or decreased the current pressure setting at step172. If so, the controller120updates and displays the current pressure setting at step176, thus setting the current pressure setting as a new displayed pressure setting, and returns to step158. If, at step174, the displayed pressure setting is equal to the current pressure setting, the controller120determines if the current pressure setting has been saved at step178. If so, the controller120returns to step158. If not, the controller120saves the current pressure setting to memory124at step180and returns to step158.

The controller120can continue returning to step158and looping through the method150ofFIG.6until the hydraulic pump102is put to sleep. For example, the controller120can put the hydraulic pump102to sleep based on the user providing a command through the user interface118. As another example, the controller120can put the hydraulic pump102to sleep automatically, such as when no inputs have been received after a set time period.

By the term “about” or “substantially” with reference to amounts or measurement values described herein, it is meant that the recited characteristic, parameter, or value need not be achieved exactly, but that deviations or variations, including for example, tolerances, measurement error, measurement accuracy limitations and other factors known to those of skill in the art, may occur in amounts that do not preclude the effect the characteristic was intended to provide.