Variable hydraulic pressure relief systems and methods for a material handling vehicle

1. A method for controlling a hydraulic control system of a material handling vehicle, the hydraulic control system including a pump having a pump outlet in fluid communication with a supply passage, a reservoir in fluid communication with a return passage, one or more hydraulic actuators configured to raise and lower a fork assembly attached to a mast of the material handling vehicle, a variable pressure relief valve configured to selectively provide fluid communication from the supply passage to the reservoir, and a controller in communication with the variable pressure relief valve and a pressure sensor configured to measure a pressure in the supply passage, the method comprising:

calibrating the hydraulic control system by performing steps of:

controlling, with the controller, the variable pressure relief valve to move to a fully open position;

increasing, with the pump, a fluid pressure upstream of the variable pressure relief valve;

controlling, with the controller, the variable pressure relief valve to move from the fully open position toward a fully closed position by adjusting a control signal supplied to the variable pressure relief valve;

monitoring, with the controller, a pressure detected by the pressure sensor; and

recording, with the controller, a parameter of the control signal supplied to the variable pressure relief valve when the pressure detected by the pressure sensor reaches a target pressure.

2. The method of claim 1 , wherein calibrating the hydraulic control system further comprises steps for:

determining, with the controller, if there is at least one additional target pressure.

3. The method of claim 1 , wherein calibrating the hydraulic control system further comprises steps of:

controlling, with the controller, the variable pressure relief valve to continue to move from the fully open position to a fully closed position after the target pressure is detected by the pressure sensor; and

recording, with the controller, a parameter of the control signal supplied to the variable pressure relief valve when the pressure detected by the pressure sensor reaches an additional target pressure.

4. The method of claim 1 , wherein the step of adjusting a control signal supplied to the variable pressure relief valve comprises adjusting a current magnitude of the control signal supplied to the variable pressure relief valve, and wherein the parameter of the control signal is the current magnitude of the control signal.

5. The method of claim 1 , wherein the step of increasing a fluid pressure comprises instructing a motor driving the pump to run at a maximum pump motor speed.

6. The method of claim 1 , wherein controlling, with the controller, the variable pressure relief valve to move to a fully open position comprises:

supplying, via the controller, a minimum current magnitude to a solenoid of the variable pressure relief valve.

7. The method of claim 1 , wherein controlling, with the controller, the variable pressure relief valve to move from the fully open position toward the fully closed position by adjusting the control signal supplied to the variable pressure relief valve comprises:

incrementally increasing a current supplied to a solenoid of the variable pressure relief valve.

8. The method of claim 1 , wherein the hydraulic control system includes a control valve arranged on the supply passage, and wherein the pressure sensor is arranged between the control valve and the one or more hydraulic actuators.

9. The method of claim 8 , wherein the variable pressure relief valve is configured to selectively provide fluid communication from a location on the supply passage arranged between the pump and the control valve to the reservoir.

10. A method for controlling a hydraulic control system for a material handling vehicle, the hydraulic control system including a pump having a pump outlet in fluid communication with a supply passage, a reservoir in fluid communication with a return passage, one or more hydraulic actuators configured to raise and lower a fork assembly attached to a mast of the material handling vehicle, a variable pressure relief valve configured to selectively provide fluid communication from the supply passage to the reservoir, and a controller in communication with the variable pressure relief valve and a pressure sensor configured to measure a fluid pressure in the supply passage, the method comprising:

calibrating the hydraulic control system by performing steps of:

supplying, via the controller, a minimum current magnitude to a solenoid of the variable pressure relief valve;

commanding a motor driving the pump to run at a maximum pump motor speed thereby increasing a pressure in the supply passage;

incrementally increasing a magnitude of a current supplied to the solenoid of the variable pressure relief valve, thereby further increasing the pressure in the supply passage;

determining, as the magnitude of current supplied to the solenoid is incrementally increased, if a pressure measured by the pressure sensor reaches a target pressure; and

upon determining that the pressure measured by the pressure sensor reaches the target pressure, recording the magnitude of current supplied to the solenoid that corresponds with the target pressure.

11. The method of claim 10 , wherein calibrating the hydraulic control system further comprises steps for:

determining, with the controller, if there is at least one additional target pressure.

12. The method of claim 10 , wherein calibrating the hydraulic control system further comprises steps of:

continuing to increase the magnitude of current supplied to the solenoid after the target pressure is reached; and

recording another magnitude of current supplied to the solenoid when the pressure measured by the pressure sensor reaches an additional target pressure.

13. The method of claim 10 , wherein the hydraulic control system includes a control valve arranged on the supply passage, and wherein the pressure sensor is arranged between the control valve and the one or more hydraulic actuators.

14. The method of claim 13 , wherein the variable pressure relief valve is configured to selectively provide fluid communication from a location on the supply passage arranged between the pump and the control valve to the reservoir.

15. A hydraulic control system for a material handling vehicle, the material handling vehicle including a pump having a pump outlet in fluid communication with a supply passage, a reservoir in fluid communication with a return passage, one or more hydraulic actuators configured to raise and lower a fork assembly attached to a mast of the material handling vehicle, the hydraulic control system comprising:

a variable pressure relief valve configured to selectively provide fluid communication from the supply passage to the reservoir when a pressure upstream of the variable pressure relief valve exceeds a variable pressure threshold;

a controller in communication with a pressure sensor, a height sensor, and the variable pressure relief valve, wherein the pressure sensor is configured to measure a pressure in the supply passage, and the height sensor is configured to measure a height of the fork assembly, the controller being configured to set the variable pressure threshold based on the height of the fork assembly by supplying a control signal to the variable pressure relief valve, and

wherein the controller is configured to calibrate the hydraulic control system by performing the steps of:

commanding the variable pressure relief valve to move to a fully open position;

controlling the pump to increase a pressure in the supply passage;

controlling the variable pressure relief valve to incrementally move from the fully open position toward a fully closed position by adjusting the control signal supplied to the variable pressure relief valve;

monitoring the pressure detected by the pressure sensor; and

recording a parameter of the control signal supplied to the variable pressure relief valve when the pressure detected by the pressure sensor reaches a target pressure.

16. The hydraulic control system of claim 15 , wherein the variable pressure relief valve includes a solenoid configured to receive the control signal.

17. The hydraulic control system of claim 16 , wherein the parameter of the control signal is a magnitude of current supplied to the solenoid.

18. The hydraulic control system of claim 16 , wherein the fully open position corresponds with a minimum current magnitude supplied to the solenoid.

19. The hydraulic control system of claim 15 , wherein a control valve is arranged on the supply passage, and wherein the pressure sensor is arranged between the control valve and the one or more hydraulic actuators.

20. The hydraulic control system of claim 19 , wherein the variable pressure relief valve is configured to selectively provide fluid communication from a location on the supply passage arranged between the pump and the control valve to the reservoir.