Actuator Calibration Using Fluid Tank Level Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing actuator calibration methods in construction machines do not effectively address the issue of setting the correct initiation current, leading to inadequate responsiveness due to wear or operating outside specified tolerances, and rely on additional components that may fail or wear out, such as pressure measuring devices.
Innovation Solution
A method and system where a controller commands actuation of an actuator, determines changes in the fluid level of a machine's fluid tank, and sets the initiation current based on these changes, eliminating the need for additional sensors and improving responsiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pressure measuring devices are used to monitor the degree of tip, then the degree of tip can be monitored, but additional components are introduced that may wear or fail
Solution Approach 1:
The patent extracts the tip monitoring function from dedicated pressure measuring devices and relocates it to the fluid level sensor that already exists in the system. By taking out the monitoring function from its original complex implementation and placing it in a simpler, more reliable location (fluid level sensor), the system eliminates the need for additional pressure sensors while maintaining monitoring capability
Solution Approach 2:
The fluid level sensor is given a dual function: it continues to monitor fluid levels in the hydraulic tank while simultaneously serving as a gauge for the degree of tip. This multi-functionality eliminates the need for separate pressure measuring devices, reducing component count and improving reliability
2Ease of operation
If initiation current is commanded without calibration, then actuator can be controlled, but responsiveness is inadequate due to wear or operating outside tolerances
Solution Approach 1:
The patent implements a calibration feedback mechanism where the controller monitors fluid level changes in response to actuator commands. By measuring the actual fluid level change and comparing it to expected values, the system determines the true initiation current for each actuator, ensuring accurate responsiveness even after wear or tolerance drift
Solution Approach 2:
The system dynamically determines and adjusts the initiation current parameter for each actuator based on actual performance measurements. Instead of using fixed or nominal current values, the calibration process identifies the specific current threshold that actually triggers actuator movement, adapting to wear and tolerance variations
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for accurate calibration of the initiation current without relying on additional sensors, enhancing the responsiveness and reliability of the actuator by using the fluid level as an indicator, thus reducing the risk of component failure and wear.
Implementation Method 1
a sensor configured to measure a fluid level in a fluid tank of a machine
Implementation Method 2
an actuator that, when actuated, affects a level of the machine
Data Source
AI summary
A calibration system is disclosed. The calibration system may include a sensor configured to measure a fluid level in a fluid tank of a machine, an actuator that, when actuated, affects a level of the machine, and a controller. The controller may be configured to: command actuation of the actuator at a current; receive, from the sensor and after commanding actuation of the actuator, information identifying the fluid level in the fluid tank; determine, based on the information identifying the fluid level in the fluid tank, whether there is a change to the fluid level in the fluid tank; and set an initiation current for the actuator at the current based on determining whether there is the change to the fluid level in the fluid tank.