Collaborative Multi-Sensor Fusion for Intelligent Flow Regulation and State Monitoring in Digital Plunger Pumps

Area of Science:

• Mechanical Engineering
• Fluid Power Systems
• Control Systems

Background:

• Traditional high-pressure, large-flow emulsion pump stations struggle with drastic flow rate changes in hydraulic supports due to fixed pump displacement.
• This leads to frequent system unloading, severe impacts, and damage, necessitating a more adaptive and intelligent solution.

Purpose of the Study:

• To propose and develop an intelligent flow control method based on digital flow distribution for active perception and matching of hydraulic support demands.
• To create a compact, electro-hydraulically separated prototype with stepless flow regulation for enhanced performance and reliability.

Main Methods:

• Developed a prototype integrating high-speed switching solenoid valves, a piston push rod, a plunger pump, sensors, and a controller.
• Implemented an optimized combined regulation strategy using adjustable duty cycles to monitor piston position and dynamically adjust valve switching.
• Employed co-simulation and experimental validation to analyze dynamic coupling and optimize system reliability by examining parameters like reset spring stiffness and piston cylinder diameter.

Main Results:

• The system achieved a flow regulation range of 83% under load and 57% without load, extending the effective pump flow range to 20-100%.
• Demonstrated significant reductions in flow root mean square error (53.4 L/min vs. 357.2 L/min) and fluctuation amplitude (±3.5 L/min vs. ±12.8 L/min) compared to traditional methods.
• Achieved 15-20% energy efficiency improvement due to reduced overflow losses and enabled intelligent, on-demand supply of dynamic flow and pressure.

Conclusions:

• The proposed intelligent flow control method and its associated electro-hydraulically separated structure provide a practical solution for upgrading fluid supply systems in mechanized mining.
• The multi-cycle optimized regulation strategy based on digital displacement pump technology effectively achieves accurate, smooth, and stable pump output matching support demands.
• The system offers fast response, high energy efficiency, and intelligent operation, marking a significant advancement over traditional unloading methods.