Patent Publication Number: US-2022213905-A1

Title: Motor cooling via hydraulic fluid

Description:
The present invention relates to a hydraulic system for driving an actuator, and in particular to a hydraulic system for driving an actuator with an alternative type of motor cooling. 
     In order to provide a volume flow in a hydraulic system, in the prior art, a hydraulic machine driven by an electric motor is usually used. Continuous operation of the electric motor leads to it becoming warm or heating up, and, accordingly, the electric motor must be cooled in order to prevent damage—which may be connected to an overloading of a motor. 
     In the prior art, there are a variety of different possibilities for providing cooling for an electric motor. The hydraulic system usually has a cooling circuit which is arranged around the housing of the electric motor. The cooling circuit is in this case an independent circuit, which, according to the prior art, can be controlled independently of the other circuits in the hydraulic system with regard to pressure, volume, etc. 
     Furthermore, in the prior art, water is often used for cooling the electric motor. However, since conventional electric motors have a housing made of aluminum, corrosion often occurred in the housing. Consequently, the electric motor housings had to be manufactured from stainless steel, which, however, leads to higher costs and also to a greater weight of the electric motor. 
     Alternatively, in the cooling circuits of the prior art, a coolant is used, which is, however, also expensive. Furthermore, the strict separation of the cooling circuit from the further circuits of the hydraulic system must be ensured, since mixing the coolant with the hydraulic fluid must at all costs be prevented during operation of the hydraulic system. 
     A separate and independent cooling circuit requires its own control system and, accordingly, an increased number of devices. In particular, a volume flow of the coolant must be provided in the cooling circuit, as a result of which further pump units with at least one motor typically need to be arranged in or at the cooling circuit. 
     It is therefore an aim of the present application to provide an alternative motor cooling in which the disadvantages of the prior art are at least partially avoided. 
     These and further aims are at least partially achieved by a hydraulic system according to independent claim  1 . Preferred embodiments and developments of the hydraulic system according to the invention are the subject matter of the dependent claims. 
     The hydraulic system according to the invention comprises a hydraulic circuit having a low-pressure region and a high-pressure region; a volume- and/or speed-variable hydraulic machine, which is driven by a first electric motor and has an inlet and an outlet and provides a volume flow of a hydraulic fluid in the high-pressure region of the hydraulic circuit. 
     Furthermore, the hydraulic system according to the invention comprises at least one movable shaft, which is arranged in the high-pressure region of the hydraulic circuit; at least one valve, which separates the high-pressure region from the low-pressure region, and at least one hydraulic fluid container, which is hydraulically connected to the low-pressure region of the hydraulic circuit. 
     The hydraulic system according to the invention further has a discharge line which discharges hydraulic fluid from leakage of the hydraulic machine, and a cooling line for transporting the hydraulic fluid for cooling the electric motor, wherein the discharge line and the cooling line are fluidically connected to at least one of the hydraulic fluid containers. 
     According to the invention, for operating a shaft, a hydraulic system is accordingly provided which has both a low-pressure region and a high-pressure region, wherein the at least one shaft is arranged in the high-pressure region. In order to provide a volume flow in the high-pressure region, and thus for the operation of the shaft, a hydraulic machine driven by an electric motor is used. 
     Electric motors, such as are used in the hydraulic system according to the invention, are known in the prior art and serve to drive the hydraulic machine. 
     The hydraulic machine is volume- and/or speed-variable and, during operation, can preferably provide two flow directions of the hydraulic fluid in the hydraulic circuit. The hydraulic machine may further have either an electric motor with variable speed and a fixed displacement pump, or an electric motor with constant speed and a variable displacement pump, or an electric motor with variable speed and a variable displacement pump. The selection of the hydraulic machine is in this case determined by factors such as system costs, efficiency, reliability, permitted noise emission, or efficiency. 
     The low-pressure region has a pre-pressurized hydraulic fluid with a pressure which lies between the ambient pressure (normal pressure 1.013 bar) and 50 bar. It is advantageous in this case for the hydraulic fluid in the low-pressure region to have a pressure of between 0.5 bar and 40 bar—in particular, between 1 bar and 30 bar, and, particularly preferably, between 10 bar and 25 bar. 
     According to an embodiment according to the invention, the hydraulic fluid can, in the low-pressure region, accordingly have an increased pressure (&gt;20 bar), but below 50 bar, or a lower pressure (&lt;20 bar). In contrast, the hydraulic fluid in the high-pressure region can have a pressure of up to 200 bar and is always above the level of the low-pressure region. 
     The shaft of the hydraulic system according to the invention is movable longitudinally and has at least one chamber. The movement of the shaft, i.e., preferably of a hydraulic piston, is provided by means of the hydraulic fluid entering or exiting at least one chamber(s) of the shaft and the associated pressure build-up or pressure reduction. The shaft is arranged in the high-pressure region of the hydraulic circuit and hydraulically connected thereto. 
     According to the invention, the shaft can be a hydraulic cylinder, a differential cylinder, a telescopic cylinder, a multi-gear cylinder, a combination of these, or the like. Furthermore, two, three, or more shafts may also be part of the hydraulic system. 
     The separation of the high-pressure region from the low-pressure region is provided by means of at least one valve. Furthermore, in the low-pressure region, at least one hydraulic fluid container is arranged which is hydraulically connected to the low-pressure region of the hydraulic circuit. 
     According to an embodiment according to the invention, the at least one valve is a check valve—in particular, a controlled check valve. The valve can be controlled either electrically or hydraulically. 
     The at least one hydraulic fluid container can provide the pre-pressurization of the system, and, in particular, the pre-pressurization of the low-pressure region. The hydraulic fluid container can, for example, be a pressure accumulator which has a hydraulic fluid to which a pressure is applied. The pressure of the hydraulic fluid in the pressure accumulator is essentially the pressure which the hydraulic fluid has in the lines of the low-pressure region. 
     Furthermore, the hydraulic fluid container can also be a pressure accumulator of variable volume, whereby a pressure build-up, and thus a pre-pressurization of the low-pressure region of the hydraulic system, can be regulated and controlled. 
     Furthermore, the hydraulic system according to the invention has a discharge line, which discharges hydraulic fluid from leakage of the hydraulic machine, and a cooling line, through which flows hydraulic fluid, which serves to cool the hydraulic machine. According to the invention, both the discharge line and the cooling line are fluidically connected to at least one of the hydraulic fluid containers. 
     The leakage from a hydraulic pump is a volume flow which, despite the existing seals, emerges from the pressure areas of the pump without performing any useful work. The size of the leakage flow depends, in addition to geometric variables of the leakage point, upon the pressure difference between the pressure chamber and its surroundings, as well as upon the viscosity of the escaping medium and its temperature. 
     These leakage flows are usually ignored, with the leakage being lost, or being collected and used elsewhere. Where appropriate, the leakage can also be fed back into the hydraulic system by means of an additional pump unit. 
     The hydraulic system according to the invention has a discharge line which is arranged on the hydraulic machine and which forwards the leakage or leakage flow resulting from the operation of the hydraulic machine. 
     Furthermore, a cooling line is arranged in the hydraulic system according to the invention. This serves in particular for cooling the electric motor and preferably runs in and/or on the housing of the electric motor and cools it. 
     According to the invention, the discharge line and the cooling line are fluidically connected to at least one of the hydraulic fluid containers. This means, in particular, that the discharge line and the cooling line are fluidically connected to the low-pressure region. 
     In the present invention, the term, “fluidically connected,” is understood to mean a connection through which fluid—in particular, a hydraulic fluid—can flow. In particular, “fluidically connected” means that the connection is not necessarily direct, but that further devices can also be interposed. For example, if it is disclosed that “device A is fluidically connected to device B,” this means that fluid can flow from A to B, wherein further devices, such as further valves, through which the hydraulic fluid can flow, can also be arranged between the device A and the device B. 
     According to one embodiment according to the invention, the discharge line and the cooling line are fluidically connected in series or in parallel to at least one of the hydraulic fluid containers. 
     Both alternatives are advantageous for the hydraulic system according to the invention. If the discharge line and the cooling line are connected in series to the hydraulic fluid container, the hydraulic fluid from the leakage will preferably be used as coolant for the motor. 
     In particular, the hydraulic fluid flows from the leakage via the discharge line into the cooling line of the electric motor, and thus in and/or on the housing of the electric motor, whereby the latter is cooled. 
     According to a preferred embodiment, the flow of the hydraulic fluid out of the leakage occurs due to the leakage pressure of the hydraulic fluid. In particular, the pressure of the leakage changes in proportion to the pressure at which the hydraulic machine works. However, the pressure of the leakage is always higher than the pressure of the low-pressure region. 
     This embodiment is cost-saving, since the hydraulic fluid from the leakage is not only returned to the hydraulic system, but is also used as a coolant. Thus, no separate coolant is required for cooling the electric motor, as a result of which material costs and coolant costs are saved. Furthermore, this reduces maintenance work and outlay on the entire hydraulic system. 
     If the discharge line and the cooling line are arranged in parallel, the leakage fluid will be re-used, which also leads to cost savings. Since the cooling line is fluidically connected to the low-pressure region, likewise in this embodiment according to the invention, hydraulic fluid is used instead of coolant to cool the electric motor. 
     According to a further embodiment according to the invention, an inlet is hydraulically connected to the hydraulic circuit in the low-pressure region. In a further embodiment according to the invention, the discharge line and/or the cooling line are hydraulically connected to the hydraulic circuit in the low-pressure region. 
     Furthermore, the inlet can be hydraulically connected to the discharge line and/or to the cooling line. 
     According to a further embodiment according to the invention, a second hydraulic machine that is volume- and/or speed-variable and driven by an electric motor is arranged in the inlet of the discharge line and/or of the cooling line. 
     The connection of the inlet to the discharge line and/or cooling line improves the flow of the leakage and/or the hydraulic fluid in the cooling line. In particular, control of the flow in the discharge line and/or cooling line is improved by using a further hydraulic machine, so that, according to a further embodiment according to the invention, the second hydraulic machine controls the hydraulic fluid flow as a function of the temperature of and/or the load on the electric motor. 
     For example, sensors that measure the temperature of the electric motor and forward it to a control unit could be connected to the electric motor housing. Consequently, the control unit can regulate or control the flow of the hydraulic fluid in the leakage and/or cooling line via the second electric motor as a function of the measured temperature. Furthermore, it is possible for the control unit to control or regulate the flow of the hydraulic fluid as a function of a measured load on the electric motor. 
     Furthermore, in accordance with another embodiment of the hydraulic system according to the invention, a restrictor is arranged at the inlet of the discharge line and/or of the cooling line. 
     If the discharge line and the cooling line are arranged in parallel to one another, and a restrictor is arranged both at the inlet of the discharge line and at the inlet of the cooling line, it will then be possible to control the volume flow and the velocity of the flow in the discharge line and cooling line by means of the restrictors. In particular, it is thus possible to control which of the two lines (discharge line and/or cooling line) requires a higher volume flow. If the electric motor becomes too warm, the flow through the discharge line can be reduced with the restrictor, for example, and the flow through the cooling line thus be increased. 
     In a further embodiment according to the invention, a hydraulic fluid container is arranged in the low-pressure region. In this embodiment, it is assumed that only one hydraulic fluid container is arranged in the hydraulic system. Furthermore, the one hydraulic fluid container according to a further embodiment according to the invention can be a closed container—in particular, a pressure accumulator. Here, the pressure of the hydraulic fluid in the pressure accumulator is comparable to the pressure of the hydraulic fluid in the low-pressure region of the hydraulic circuit. In particular, the pressure accumulator serves to pre-pressurize the hydraulic fluid in the low-pressure region. 
     According to a further embodiment according to the invention, the hydraulic system has a further hydraulic fluid container, which is also arranged in the low-pressure region. Thus, according to a further embodiment, the first hydraulic fluid container can be a closed container—in particular, a pressure accumulator, as mentioned above—and the further hydraulic fluid container can be a non-pressurized—in particular, open—container. 
     In the following, the term, “non-pressurized,” refers to an ambient pressure, which is usually about 1 bar (1.013 bar). 
     Since the pressure of the hydraulic fluid in the open container is lower than the pressure of the hydraulic fluid in the low-pressure region, a further hydraulic machine can be arranged according to a further embodiment according to the invention between the low-pressure region of the hydraulic circuit and the further hydraulic fluid container. This serves to feed hydraulic fluid into the low-pressure region from the further hydraulic fluid container or from the open tank. 
     By using an open container as the second hydraulic fluid container, cooling of the hydraulic fluid in the tank is provided. 
     According to a further embodiment according to the invention, the discharge line and the cooling line are thus fluidically connected to the second hydraulic fluid container. Accordingly, the discharge line and the cooling line are fluidically connected, via the inlet, to the low-pressure region of the hydraulic circuit and the first closed container, i.e., to the first hydraulic fluid container, and are simultaneously fluidically connected to the further, second, open hydraulic fluid container. 
     Consequently, in this embodiment according to the invention, the hydraulic fluid from the leakage and out of the cooling line is passed into the further hydraulic fluid container - in particular, into the open tank. From the further hydraulic fluid container, the cooled hydraulic fluid is fed back into the lines of the low-pressure region by means of the further hydraulic machine. 
     Furthermore, according to a further embodiment according to the invention, the inlet of the discharge line and/or the inlet of the cooling line are also fluidically connected to the further hydraulic fluid container. 
     This is followed by the hydraulic fluid, which is used for cooling and flows into the further hydraulic fluid container. This is advantageous, since the possibly highly-heated hydraulic fluid, which was used for cooling, can thus “cool down” in the second hydraulic fluid container, wherein cooling is improved when the further hydraulic fluid container is an open tank. 
     According to a further embodiment according to the invention, a cooler is arranged in the low-pressure region and/or in/at the inlet or in/at the discharge line or in/at the cooling line, or in/at one of the hydraulic fluid containers. 
     The heated hydraulic fluid can be cooled more quickly by the cooler, and thus be re-used in the hydraulic system. In addition, the use of a closed hydraulic fluid container, instead of an open tank, for the further hydraulic fluid container is thus possible. This saves space, since open tanks are usually bigger than pressure accumulators. Furthermore, the amount of hydraulic fluid required is thus reduced. 
     However, if the further hydraulic fluid container is an open tank, the use of a cooler has the advantage that the tank can be smaller. 
     Furthermore, filter devices and/or air vents can also be arranged in the low-pressure region of the hydraulic system. 
     According to all of the aforementioned embodiments, a method for using the hydraulic circuit is claimed according to the invention in which a hydraulic fluid—in particular, at least partially from leakage of the hydraulic machine—is used for cooling the hydraulic machine and/or the electric motor. 
     The invention is explained below on the basis of various exemplary embodiments, wherein it is pointed out that these examples encompass modifications or additions that are immediately apparent to the person skilled in the art. 
    
    
     
       The following are shown: 
         FIG. 1 : a schematic representation of a system according to the invention; 
         FIG. 2 : a schematic further exemplary embodiment of the system according to the invention; 
         FIG. 3 : another exemplary embodiment of the hydraulic system, with a discharge line and cooling line arranged in parallel; 
         FIG. 4 : an embodiment of the hydraulic system from  FIG. 1 , comprising a further hydraulic fluid container; 
         FIG. 5 : a schematic further exemplary embodiment of the system according to the invention from  FIG. 4 ; 
         FIG. 6 : a schematic further exemplary embodiment of the system according to the invention from  FIG. 4 ; 
         FIG. 7 : yet another embodiment of the hydraulic system according to the invention. 
     
    
    
       FIG. 1  shows an exemplary embodiment according to the invention of the hydraulic system  1 . As can be seen from the figure, the hydraulic system can be divided into two regions: a low-pressure region  2 , in which the hydraulic fluid has a low pressure—in particular, a pressure between ambient pressure and 30 bar—and a high-pressure region  4 , in which the hydraulic fluid has a high pressure—in particular, above 30 bar—which is used to move a shaft  20  arranged in the hydraulic system and connected to the high-pressure region  4  of the hydraulic system  1 . 
     The hydraulic system  1  has a first electric motor  10  and a hydraulic machine  11  driven by the electric motor  10 . This is arranged in the high-pressure region  4  and serves to provide a volume flow of the hydraulic fluid in the shaft  20 . The shaft is shown as a double-acting hydraulic cylinder with two chambers. The hydraulic machine has two outputs or inputs, each of which is connected to a chamber of the shaft  20 . The hydraulic machine can thus convey hydraulic fluid from one chamber of the shaft  20  into the other chamber of the shaft  20 , whereby a movement of the shaft  20  is provided. 
     The high-pressure region  4  and the low-pressure region  2  are separated from one another by means of unlockable check valves  30 . 
     Due to the continuous operation of the hydraulic machine  11 , leakages occur at the hydraulic machine  11 , as a result of which the volume of hydraulic fluid in the high-pressure region  4  drops. By precisely adjusting the spring strength in the check valves  30  or by electrical unlocking, the missing volume of hydraulic fluid can be conducted from the low-pressure region  2  into the high-pressure region  4 . 
     According to  FIG. 1 , a hydraulic fluid container  50 , which is designed as a pressure accumulator  50 , is hydraulically connected to the low-pressure region  2  of the hydraulic system  1 . 
     As shown in  FIG. 1 , the hydraulic system  1  comprises a discharge line  62  which is connected to the leakage or to the leakage collection area of the hydraulic machine in such a way that the leakage fluid can be fed back into the low-pressure region through the discharge line. 
     In this respect, according to this exemplary embodiment according to the invention, the discharge line  62  has been connected to the cooling line  64  of the electric motor so that the leakage fluid is used as coolant for the electric motor  11 . In this example, the discharge line and the cooling line are thus arranged in series. The cooling line  64  is in turn fluidically connected to the low-pressure region  2  and, in particular, fluidically connected to the hydraulic fluid container  50 . The leakage fluid is thus used for cooling and subsequently fed back into the system. 
       FIG. 2  shows an alternative exemplary embodiment of the hydraulic system  1  according to the invention from  FIG. 1 . 
     While the general design of the embodiment according to  FIG. 2  corresponds to the design of  FIG. 1 , the hydraulic system of  FIG. 1  furthermore comprises an inlet  66  and a second electric motor  100  with a second hydraulic machine  110  driven by the electric motor. 
     The inlet  66  is connected to the leakage area via the housing of the hydraulic machine  11 , which is hydraulically connected in series to the discharge line  62  as in  FIG. 1 . 
     The inlet  66  is furthermore fluidically connected to the low-pressure region  2  via the second hydraulic machine  110 . An improved control of the volume flow through the discharge line and/or the cooling line can thus be achieved by means of the hydraulic machine  110 . 
       FIG. 3  shows another exemplary alternative embodiment according to the invention of  FIG. 2 . In this exemplary embodiment, the discharge line  62  and the cooling line  64  are arranged in parallel so that both lines are hydraulically connected to the low-pressure region  2 . By contrast, the inlet  66  is hydraulically connected, via a restrictor  70   b,  to the cooling line and thus to the housing of the electric motor  10 , and, via a further restrictor  70   a,  to the discharge line. The inlet  66  is connected to the low-pressure region  2  via the hydraulic machine  110 . The restrictors  70   a  and  70   b  thus serve to regulate the volume flow in the discharge line  62  and/or the cooling line  64 . 
       FIG. 4  shows another exemplary embodiment according to the invention of the hydraulic system  1  from  FIG. 1 . 
     As can be seen from  FIG. 4 , the following exemplary embodiment according to the invention has a further hydraulic fluid container  52  which, in contrast to the first hydraulic fluid container  50 , is an open tank. The open tank  52  is also fluidically connected to the low-pressure region  2 . 
     According to this exemplary embodiment according to the invention, the cooling line  64  and the discharge line  62  are connected to one another in series. Furthermore, they are fluidically connected to the hydraulic fluid container  52  so that hydraulic fluid flows from the leakage area of the hydraulic machine  11 , through the cooling line of the electric motor  10 , and then into the hydraulic fluid container  52 . 
     Furthermore, a further hydraulic machine  220  driven by an electric motor  200  is arranged between the hydraulic fluid container  50  and the low-pressure region  2 . The hydraulic machine provides a fluid flow from the further hydraulic fluid container  52  into the low-pressure region  2 . 
     The further structure of the exemplary embodiment according to the invention from  FIG. 4 , and, in particular, the structure of the high-pressure region, corresponds to the exemplary embodiment of the hydraulic system  1  from  FIG. 1 . 
       FIG. 5  shows yet another exemplary embodiment according to the invention of the hydraulic system  1 . 
     As can be seen from the figure, a second hydraulic fluid container  52  is also fluidically connected here to the low-pressure region of the hydraulic system via an additional hydraulic machine  210 . Furthermore, the discharge line  62  and the cooling line  64  are fluidically connected in series and to the hydraulic fluid container  52 . 
     In contrast to  FIG. 4 , in this system of  FIG. 5 , an inlet  66  is connected to the discharge line  62  of the hydraulic machine  11 . This inlet is furthermore hydraulically connected to the low-pressure region  2  of the hydraulic system  1 . A restrictor  70  is arranged in the inlet and regulates or controls the flow of the hydraulic fluid into the discharge line  52 . 
       FIG. 6  is similar to  FIG. 5 , wherein, in this exemplary embodiment according to the invention, the discharge line and the cooling line are fluidically connected in parallel to a line  68  which itself is hydraulically connected to the second hydraulic fluid container  52 . 
     Furthermore, the inlet  66  is fluidically connected to the discharge line  62  via a restrictor  70   a  and to the cooling line  64  via a second restrictor  70   b . Furthermore, the inlet is fluidically connected to the low-pressure region  2  of the hydraulic system  1 . 
       FIG. 7  shows another exemplary embodiment according to the invention of the hydraulic system  1 . 
     As already shown in the previous embodiments, a further hydraulic fluid container  52 , with an open design, is arranged in the low-pressure region  2  of the hydraulic circuit  1  via a hydraulic machine  210 . 
     The discharge line  62  and the cooling line  62  are arranged in series and are fluidically connected to the hydraulic fluid container  52  via a line  68 . An inlet  66  is fluidically connected to the cooling line  64  at one end and to the hydraulic fluid container  52  at the other end via a further hydraulic machine  310 , which is driven by a further, third electric motor  300 . The hydraulic fluid required for cooling is thus still obtained from the low-pressure region  2 .
       1  Hydraulic system     2  Low-pressure region     4  High-pressure region     10  First electric motor     11  Hydraulic machine     20  Shaft     30  Check valve     50  First hydraulic fluid container     52  Second hydraulic fluid container     62  Discharge line     64  Cooling line     66 ,  66   a,    66   b  Inlet     68  Line     70 ,  70   a,    70   b  Restrictor     100  Second electric motor     110  Second hydraulic machine     200  Electric motor     210  Hydraulic machine