Actuator Brake Capacity Assessment for Stable Power-Down Loads

Solution Overview

Problem

Existing power machines, particularly electric power machines, lack effective methods for monitoring and controlling actuator brake performance, leading to uncertainties in maintaining load stability during power-down sequences and scheduling maintenance, which can result in unintended load movement.

Innovation Solution

Implementing systems and methods to control and analyze the electric current of an actuator brake, using positional deviation and current trace to determine performance metrics such as holding capacity, and providing real-time feedback to operators for informed maintenance and safe power-down sequences.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If brake capacity is not monitored, then the system is simpler, but load stability cannot be ensured during power-down sequences

Engineering Contradiction:

Improveload stabilityVSAvoidmonitoring system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system continuously monitors the position of the work element during power-down sequences and feeds this information back to the control device. When positional deviation exceeds a threshold, the system automatically responds by adjusting the actuator's electric current to compensate for brake capacity不足, thereby ensuring load stability without requiring complex additional hardware

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The control device uses the existing position sensor and processing capabilities already present in the electric actuator system to perform brake capacity monitoring and evaluation. The system leverages its own existing resources to detect brake performance degradation and automatically adjusts operating parameters, eliminating the need for separate dedicated monitoring hardware

Inventive Principle:

Principle #25Self-service

2Reliability

If brake performance is not evaluated, then maintenance scheduling is simpler, but unintended load movement may occur

Engineering Contradiction:

Improvebrake performanceVSAvoidperformance evaluation system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system continuously monitors the position of the work element during power-down sequences and feeds this information back to the control device. When positional deviation exceeds a threshold, the system automatically responds by adjusting the actuator's electric current to compensate for brake capacity不足, thereby ensuring load stability without requiring complex additional hardware

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The control device uses the existing position sensor and processing capabilities already present in the electric actuator system to perform brake capacity monitoring and evaluation. The system leverages its own existing resources to detect brake performance degradation and automatically adjusts operating parameters, eliminating the need for separate dedicated monitoring hardware

Inventive Principle:

Principle #25Self-service

3Use of energy by moving object

If electric current is not reduced during power-down, then power consumption is higher, but load stability cannot be maintained

Engineering Contradiction:

Improvepower consumptionVSAvoidload stability

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The system dynamically adjusts the electric current supplied to the actuator during power-down sequences based on real-time position feedback. The control device continuously evaluates positional deviation and modulates the electric current accordingly, transitioning from higher current during normal operation to reduced current when brakes are engaged, optimizing both energy consumption and load stability

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system continuously monitors the position of the work element during power-down sequences and feeds this information back to the control device. When positional deviation exceeds a threshold, the system automatically responds by adjusting the actuator's electric current to compensate for brake capacity不足, thereby ensuring load stability without requiring complex additional hardware

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS12516494B2Systems and methods of determining actuator brake capacity

Publication Date: 2026.01.06 DOOSAN BOBCAT NORTH AMERICA INC

AI summary

Methods and systems for controlling and understanding brake capabilities of an actuator for power machines are provided. One system may include activating a brake of an electric actuator to maintain a position. While the brake is activated, the system may adjust an electric current of the electric actuator. While the electric current of the electric actuator is adjusted, the system may monitor for positional deviations from the first position. When a positional deviation is detected, the system may determine a present electric current of the electric actuator and determine, based on the present electric current, a performance metric for the brake of the electric actuator.