METHOD FOR FLUSHING HEAVY EQUIPMENT HYDRAULIC SYSTEMS
RELATED PATENT APPLICATIONS: This patent application claims priority to
United States Provisional Application No. 60/027,41 5 filed October 8, 1 996 which
is entitled AGRICULTURAL EQUIPMENT FLUSHING SYSTEM.
TECHNICAL FIELD: This invention relates generally to the maintenance of
agricultural and heavy industrial equipment; more particularly, it relates to the
cleaning and replacement of lubricating and operating fluids in hydraulic systems
and/or transmission systems of those types of equipment.
BACKGROUND ART: It is well known in agricultural and heavy equipment
industries that periodic maintenance is required on both hydraulic and transmission
systems. In each of such systems, fluids are utilized in the system's operation
that through use become contaminated and require periodic exchange of used fluid
for new. Because of the "dirty" environments in which these types of equipment
are typically used, it is not uncommon for these fluids to not only become laden
with dirt particles, but other contamination and debris may also be carried in the
circulating fluid or may adhere to interior portions of the system. This
contamination of the fluid and the fluid's own degradation through use can have
detrimental effects on the systems within which they are contained. More
specifically, the operating fluids in both hydraulic and transmission systems serve
as lubricators, as well as operating fluids for each. The presence of the abrasive
particles and debris can result in damage to the various components that make up
the respective systems. If the particulate is large enough, it may also affect
operation of the system.
In maintenance procedures, it is well known to drain these systems of the
fluids contained therein. During this draining process, it is hoped that at least a
portion of the abrasive contaminants will be removed together with the spent
fluids. Unfortunately, these abrasive particles oftentimes have greater densities
than the operating fluids and therefore settle therefrom and are not drained
together with the fluids. When these situations occur, solid sediment may become
deposited within the hydraulic or transmission system and never be cleared
therefrom. As a result, increasing accumulations may form and ultimately cause
damage to the system or compromise its utility for intended purposes and its
useful life.
In view of these inadequacies associated with currently known methods for
exchanging operating fluids of hydraulic and/or transmission systems, the present
invention has been developed to alleviate the same.
DISCLOSURE OF THE INVENTION: The present invention provides means
through which a complete evacuation of both hydraulic and transmission systems
on agricultural and heavy industrial equipment may be achieved. Not only are the
operating fluids evacuated from these systems, but the components of the
systems are adequately flushed to remove substantial portions, if not all
contaminating and abrasive matter that has accumulated therein. Three cleaning
actions are made possible by the utilization of this invention. By using a rapid
injection of cleaning fluid, sediment within the system is flushed therefrom
together with the cleaning solution. This action may be repeated thereby
establishing a washing cycle so that remaining sediment becomes suspended
within the cleaning fluid and adhering contaminants are more completely dislodged
and swept from the system. On each cycle of the introduction and removal of
cleaning solution, the fluid is filtered to remove the contamination load caused by
each cycle of inward and outward movement of the fluid. In a third action,
cleaning fluid is circulated through the target system in a circuit-type fashion which
may be optionally filtered and which causes a turbulent flow through the system
that assures complete suspension of debris particles and dislodgment of adhering
contamination. After completing these several cleaning actions, fresh fluid may
be reinjected into the system thereby replenishing the spent operating fluid with
new fluid.
Not only do these actions remove dirt and other contamination from the fluid
systems, but the forced reintroduction of fluid assures that replenishment of all
fluids throughout the system is thorough. This is important because it guarantees
that there are not voids that may take the form of air pockets that can result in a
"dry" start when the equipment is initially reactivated after the fluid exchange and
flushing process. Still further, it is contemplated that these processes may be
accomplished either manually by an operator or they may be automated and
executed by a computerized controller. In either case, the present invention has
proved highly effective in accomplishing a reduction in required repair to
agricultural and heavy industrial equipment, as well as extending the useful life of
the same.
One embodiment of the present invention is a method for flushing a
hydraulic system of a heavy equipment piece. A first step of the process is to
open a drain port in a hydraulic system of the heavy equipment piece and drain
used hydraulic fluid therefrom and into a waste reservoir that is maintained exterior
to the equipment piece itself. A cleaning solution is then injected into the
hydraulic system that purges remaining undrained hydraulic fluid from the system
and into the waste reservoir. During this stage, the draining and purging fluids are
monitored and it is detected when used hydraulic fluid ceases to flow from the
system and when cleaning solution subsequently begins to flow from the hydraulic
system. When this situation is detected, the drain port is closed and cleaning
solution that continues to be injected is retained within the hydraulic system. The
accumulated cleaning solution is ultimately evacuated from the hydraulic system
and fresh replenishing hydraulic fluid is injected into the hydraulic system. The
equipment piece may then be placed back into service with fresh fluids and usually
improved performance.
Branch fluid flow paths may also be flushed using the present cleansing
system by opening the control valves for a specific feature, such as a power brake,
on a branch thereby opening the branch circuit to cleaning solution flow off of the
primary flow path that otherwise bypasses that branch. By including the flushing
of a plurality of branch paths off of the primary path, thorough cleaning of the
hydraulic system and its components is assured.
BRIEF DESCRIPTION OF THE DRAWINGS:
Figure 1 is a schematic illustration of the flushing system according to the
present invention showing the cooperation of the several components of the
system and the fluid flows through the primary and branch fluid flow paths.
MODE(S) FOR CARRYING OUT THE INVENTION:
Referring to Figure 1 , the heavy equipment piece flushing system 05 is
illustrated in schematic. Components of the flushing system, as well as of the
hydraulic system 20 and/or transmission system 22 of an agricultural or heavy
industrial equipment piece are illustrated. In the illustration of Figure 1 , a
hydraulic system 20 based on an agricultural tractor has been shown. It should
be understood, however, that the flushing concepts and devices for achieving the
same are considered to be interchangeable upon other agricultural pieces of
equipment, as well as heavy industrial and construction equipment pieces.
The hydraulic system 20 of the equipment piece includes a low pressure
side 30 and a high pressure side 40. Each of the two sides are controlled by a
main hydraulic pump 25 through which or around which the flushing action of the
first cycle in the cleaning process occurs. Each of the two pressure sides 30,40
drain to an equipment piece hydraulic fluid reservoir or bathtub 45 that serves as
a receptacle for hydraulic fluid during operation of the equipment piece and as a
collector of cleaning solution in the flushing process. The bathtub 45 includes two
reservoir drain ports 50 at lower extremities of the bathtub 45 and from which
fluid connections are possible. A waste reservoir or drain fluid catch pan 55 is
associated with the bathtub 45 and is typically positioned beneath the drain port(s)
50 so that fluid draining therefrom is caught and retained for disposal or reuse
from the catch pan 55.
Prior to any flushing process being affected on an equipment piece, the used
system fluid, in the illustrative case hydraulic fluid, is permitted to drain by gravity
therefrom. In a first action of the flushing system, the several vεlves (Vx) are
oriented so that operation of rotary pump 10a or 10b causes cleaning solution to
be withdrawn from a cleaning solution heater and reservoir 60 and pumped
through pressure hose 1 5 to the main hydraulic pump 25 of the tractor. As shown
in Figure 1 , a low pressure pump (PL) 10a is located in parallel with a high pressure
pump (PH) 10b in the primary fluid flow path 90 of the flushing system 05. Either
of the two pumps 10a, 10b may be operator selected for use based upon the
system 20,22 to be flushed.
In the case of a transmission system 22, relatively low pressures will be
sufficient to inject cleaning solution throughout the system 22 to be flushed. On
the other hand, if a hydraulic system 20 is to be flushed, significantly greater
pressures will be required for injected cleaning solution to pass through various
restrictions of the several flow paths 90,95 of the system 20 to be flushed. In the
case of a hydraulic system 20 as typified in Figure 1 , at the main hydraulic pump
25, the cleaning solution is first flushed through the low pressure side 30 of the
hydraulic system 20 and secondly through the high pressure side 40 of the system
20.
The initial flushing of the low pressure side 30 is accomplished by the
pressured cleaning solution being forced therethrough by the rotary pump 10b. In
the illustrated example, a check valve CV4 is located at the main hydraulic pump
25 that under sufficient pressure permits fluid to flow into and through the low
pressure side of the system 20. During this flushing process, the high pressure
rotary pump 10b is operated for a period of time typically lasting between two and
three minutes. Based on the volumetric rate of fluid pumped therethrough, it is
typical for approximately three gallons of cleaning solution to be passed and
flushed therethrough. At the commencement of the flushing process, one of the
drain ports 50 is opened and as explained above, the hydraulic fluid from the
system 20 is permitted to drain into a waste reservoir 55. When the high pressure
pump 1 0b is initially actuated and cleaning solution injected into the system 20,
those remnants of hydraulic fluid that had remained in the system 20 are purged
therefrom and out the drain port 50. This expression of the hydraulic fluid may be
monitored or observed so as to detect when the hydraulic fluid ceases to flow
from the system 20 and cleaning solution begins to flow. When this situation is
detected, the drain port 50 is closed. Thereafter, the cleaning solution that is
continued to be injected into the system 20 flows into the hydraulic fluid reservoir
45 of the hydraulic system 20. After this initial injection of cleaning solution, the
flow of solution is stopped and that cleaning solution accumulated in the reservoir
45 is evacuated or vacuumed therefrom using a diaphragm pump (Pv) 70. Because
the cleaning solution is now burdened with contamination and other debris, it is
filtered through a first prefilter (F^ 65 and then subsequently through a smaller
porosity after-filter (F2) 75 thereby eliminating that contamination and debris that
may harm the system 20 if it were to remain.
The cleaning solution is vacuumed from the fluid reservoir 45 back into the
original tank 60 from which it was withdrawn for reinjection and passage again
through the hydraulic system 20. At this stage, the tank 60 is considered an
accumulation tank 60 where the filtered cleaning solution is reservoired for
subsequent use. The accumulation tank 60 is the only tank actually contained
within the portable flushing system 05 and in a preferred embodiment takes the
form of a water heater or similar type device having a capability to raise and
maintain the cleaning solution at approximately 1 1 0° Fahrenheit.
Utilization of the flushing system 05 upon a hydraulic system is as simple
as making two connections; one upstream of the main hydraulic pump 25 of the
system 20 in the primary fluid flow path 90 for injecting fluid and one connection
at the drain port 50 which is typically at an extreme downstream location within
the flow path 90.
It should be appreciated, that the present flushing system 05 can be used
to flush equipment fluid systems such a transmission system 22 that does not
offer significant resistance to the injection of cleaning solution. In these situations,
the low pressure pump 1 0a will be utilized and develop sufficient pressure for the
requisite cleaning operations. In hydraulic systems 20, however, significantly
higher pressures, often exceeding 400 psi, will be required to affect the injection
of cleaning solution throughout the entire system 20 and therefore the high
pressure rotary pump 10b will be used.
After the original injection of cleaning solution and its subsequent
evacuation from the hydraulic fluid reservoir 45 into the accumulation tank 60, one
or more washing cycles may be affected wherein this process is substantially
repeated so that further cleansing of the system 20 is made possible with
rewarmed cleaning solution that is most effective at breaking down the
contamination to be removed from the system 20 and assuring that the
contamination is suspended within the cleaning solution or dissolved therein. It is
possible that this washing cycle will be sufficient to clean a given system 20,22.
If that is the case, fresh replenishing fluid will be injected into the system 20,22
using whichever pump 1 0a, 10b was used for the washing process. The
replenishing fluid is withdrawn from a fresh fluid reservoir 57 and injected into the
system 20,22 until all cleaning solution is expressed therefrom and all air pockets
are removed. By utilizing this method of expressing the cleaning fluid and all air
pockets with operating or hydraulic fluid, it is assured that a "dry" start will be
avoided when the equipment piece is placed back into service. In this way, the
present invention further avoids maintenance and extends the operational life of
the equipment being flushed. If any drainage does occur from the hydraulic
system 20, it is as designed by the manufacturer and not considered to be a
detrimental effect. This condition may be likened to equipment standing idle and
not running for a period of time between utilizations.
It is contemplated that the system to be flushed may be a transmission
system 22 alone, a hydraulic system 20 alone, or a combination system wherein
the transmission system used for moving the equipment piece about is a branch
or portion of the overall hydraulic system 20 of the equipment piece.
In some situations, the intermittent washing process described hereinabove
will not be sufficient for thoroughly cleaning the fluid passages of the target
system 20. In those cases, a cleaning solution circulation circuit may be
established using the injection pump 10 which has its intake, after an original filling
of the system 20 with cleaning solution, off of the fluid reservoir 45 wherein
cleaning solution that has passed through the system 20 is collected. By having
both the discharge and intake of the pump 10 placed at upstream and downstream
positions, respectively, within the system 20 to be flushed, a continuous flow-
circuit of cleaning solution may be established. When such a circulation is
affected, the cleaning solution will be typically heated to a sufficient temperature
that effective cleaning is accomplished. It is not expected, however, that the
circuit will include passage through the heated accumulation tank 60. The
circulation circuit will, however, include passage through both of the filters 65 and
75. In this manner, debris and contamination continue to be dislodged and
scoured from the target system 20, and that removed debris will be filtered from
the cleaning solution for more efficient cleaning as that solution continues to pass
through passages of the system 20.
As may be appreciated in Figure 1 , most hydraulic systems 20 have a
primary fluid flow path 90 through which circulation continues at most times of
operation keeping the various components supplied with lubricating fluid. There
are also branch fluid flow paths 95 off of the primary path 90 typically utilized for
driving accessories of the equipment piece. These driven accessories may range
from hydraulic brakes, to hydraulic steering systems, and to apparatus for raising
and lowering implements connected to the equipment piece such as plows and
cultivators in the instance of agricultural equipment and road scrapers as examples
of accessories to be raised and lowered on construction equipment pieces. In
either case, one or more hydraulically driven accessory or feature (Fx) may be
incorporated upon a single equipment piece. An example of three such features
(F, 2and3) are illustrated in Figure 1 . Such a branch fluid flow path 95 is illustrated
with respect to one feature, F, . In a typical configuration, a feature such as the
raising of an implement will be actuated by the opening of an inlet control valve
(VF1). This permits the passage of fluid past a check valve (CV ^ and ultimately
through or to the feature (F,). In the case of the raising of an implement, the
feature would be a reciprocating piston and cylinder configuration. The pressure
to overcome the check valve (CV,) is less than that required to overcome the
primary flow path check valve (CV4). In this way, the branch fluid flow path 95
permits cleaning solution to pass therethrough as long as the control valve (VF1)
is opened. One or more features may be flushed by the establishment of
successive branch flow paths 95. This cleansing of a plurality of features may be
simultaneously accomplished, but more typically, the control valves (VFX) will be
operated sequentially and not simultaneously thereby causing each branch to be
cleansed by circulating fluid passing therethrough, one at a time. Because the
cleaning solution passing through the branch is expressed therefrom downstream
to the primary flow path check valve (CV4), fluid flow in the direction of the
primary flow path 90 continues. The check valve (CV4) prevents backward flow
in the direction of the pump 1 0. Once the circulation is established, it may be
continued indefinitely based upon the requirements of the system 20 and the
desires of the operator.
In the illustration of Figure 1 , a transmission system 22 is shown to be in¬
line with the circuit of the hydraulic system 20. This is an optional configuration,
but one which permits a single cleaning operation of both the conventional
components of the hydraulic system 20 and the hydraulically operated portions of
the transmission system 22.
An optional configuration is accommodated based on the schematic of
Figure 1 . The main hydraulic pump 25 of some hydraulic systems 20 do not
permit for the through passage of cleaning solution into the high pressure side 40
of the system 20. In those instances, a jumper conduit 35 may be required that
connects into the hydraulic system 20 downstream from the equipment pieces
pump (PE) 25 and is controlled by a jumper valve (V^. The valve (V,) permits the
redirection of cleaning solution off of the primary fluid flow path 90 and up into
the high pressure side of the system 20 and then into one or more branch flow
paths 95. A hydraulic return circuit has been illustrated wherein a transfer pump
(Pτ) is provided through which hydraulic fluid is returned back to the primary pump
(PE) for a sufficiently high pressure boost for utilization by the pressure driven
features during regular operation of the hydraulic system 20.
In the illustration of Figure 1 , multi-directional valves (Vx) are used to
indicate the possible directions of flow therethrough. Valve (V^ is utilized for
permitting fluid flow passage through the flushing system 05 to the optional
jumper 35, if required by the system 20 being flushed. Each feature (Fx) is
controlled by an inlet control valve (VFX) that operates in conjunction with check
valves (CVX) to assure uni-directional flow through the primary and branch fluid
flow paths of the hydraulic system 20 being flushed. There are two drain ports
50, with each being controlled by one of valves (V7) and (V8). As indicated in
Figure 1 , valve (V8) opens and closes drainage to the waste reservoir while valve
(V7) completes the circuit of the primary fluid flow path 90. This is accomplished
through a return conduit 80 that causes the cleaning solution to pass through both
filters 65 and 75. When the flow of cleaning solution reaches valve (V5), it is
optionally directed toward the accumulation tank 60 when the evacuating
diaphragm pump (Pv) is operational or valve (V5) may direct the return fluid to
either the low pressure pump 1 0a or the high pressure pump 10b, whichever is
being utilized for a circulation cleaning. The selection between the pumps 10a and
10b is affected through the use of valves (V2) and (V3). The circulation of cleaning
solution back to these pumps is also permitted or prevented by valve (V4). This
same valve (V4), in conjunction with the valve (V6) determines which fluid will be
injected into the system 20 by the pumps 10a, or 10b. With the valve (V6) in one
position, cleaning solution is withdrawn from accumulation tank 60. In its other
configuration, the valve (V6) causes the withdrawal of replenishing fresh operating
fluid from the reservoir 57 and injection into the hydraulic system 20.
The high pressure pump 10b is designed and selected so that is has capacity
for delivering cleaning solution to the hydraulic system 20 at a pressure of at least
700 psi and a flow rate of at least 7 gallons per minute at that pressure. At this
rate, turbulent flow will be achieved through the passages of the hydraulic system
20 so that a scouring effect is achieved on contamination adhering to interior walls
of those passages and the flow will be sufficiently disturbed to maintain that
contamination in suspension until removed therefrom by filters 65 and 75.
Through the unique flushing processes of the present invention, it has been
discovered that repairs and scheduled maintenance may be reduced, while at the
same time extending usable and operational life expectancies. Each of these
factors prove beneficial to the equipment owners by reducing costs and minimizing
down time experienced because of equipment required repairs or failures.
INDUSTRIAL APPLICABILITY: The present invention finds utility in all industries
in which heavy equipment pieces are operated that have hydraulic or other fluid
operating systems requiring periodic exchange and replenishment of operating
fluids. Specific utility will be appreciated in the agricultural industries and the
construction industries.