Electric Actuator Load Balancing for Leveling Stability
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Solution Overview
Problem
Existing electric actuator systems for leveling objects, such as recreational vehicles, often result in uneven load distribution among actuators, leading to unstable positioning and potential swaying or shifting due to improper weight distribution, especially when some actuators carry a substantial part of the load while others do not, causing erratic movement and requiring precise synchronization.
Innovation Solution
An electric actuator system with a microprocessor-based controller that uses load sensors and temperature sensors to ensure each actuator is properly loaded, integrating electrical current sensing to determine the load carried by each actuator, and employing soft start and soft stop techniques to minimize jerking and erratic movement, allowing for automatic and manual operation across various applications with adaptable actuator configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If multiple electric actuators are used to level an object, then the positioning capability is improved, but uneven load distribution causes instability and erratic movement
Solution Approach 1:
The system incorporates load sensors on each actuator that provide real-time feedback to the controller about the load carried by each actuator. The controller uses this feedback to detect uneven load distribution and adjust actuator operation accordingly, preventing instability and erratic movement while maintaining automated leveling capability.
Solution Approach 2:
The control system dynamically adjusts the operation of individual actuators based on real-time load conditions. When uneven load distribution is detected, the controller modifies the extension/retraction commands for specific actuators to balance the load, enabling the system to adapt to changing conditions and maintain stability throughout the leveling process.
2Manufacturing precision
If some actuators carry substantial load while others do not, then the system can achieve leveling, but erratic movement and swaying occur
Solution Approach 1:
Load sensors provide continuous feedback to the controller about which actuators are carrying substantial loads. The controller uses this information to ensure all actuators participating in leveling are properly loaded, preventing the erratic movement and swaying that occur when some actuators are underloaded during the leveling process.
Solution Approach 2:
The system performs preliminary load assessment before completing the leveling operation. The controller monitors load conditions throughout the leveling process and ensures minimum load thresholds are met before final positioning, preventing erratic movement caused by improper weight distribution.
3Measurement precision
If load sensors and temperature sensors are added to each actuator, then load distribution control is improved, but system complexity increases
Solution Approach 1:
The sensor system is designed to serve multiple functions: load sensors measure both the load carried by each actuator and provide feedback for load distribution control, while temperature sensors monitor actuator conditions for both protection and optimization purposes. This multi-functionality reduces the need for separate specialized sensors and simplifies the overall system architecture despite the added measurement capabilities.
Solution Approach 2:
The controller automatically processes sensor data from all actuators and performs load balancing without requiring external intervention or complex manual configuration. The system self-regulates by comparing sensor readings and adjusting actuator commands accordingly, reducing the operational complexity despite the increased number of sensors.
4Manufacturing precision
If precise synchronization of multiple actuators is required, then positioning accuracy is improved, but control complexity and cost increase
Solution Approach 1:
The system uses load feedback from each actuator to achieve coordinated operation without requiring complex synchronization mechanisms. The controller adjusts each actuator's operation based on its load conditions, allowing the actuators to work together harmoniously and achieve accurate positioning through adaptive load balancing rather than precise timing synchronization.
Solution Approach 2:
The control system changes operational parameters (extension/retraction commands) for individual actuators based on their load conditions rather than applying uniform synchronization commands to all actuators. This parameter-based adaptive control achieves positioning accuracy by optimizing each actuator's contribution based on real-time conditions, simplifying the control approach compared to rigid synchronization requirements.
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
The system ensures stable and precise leveling of objects by ensuring each actuator carries a substantial load, minimizing erratic movement, and allowing for easy adaptation to different applications without requiring precise synchronization or additional sensors like hydraulic motor position sensors or pressure sensors.
Implementation Method 1
load sensors to ensure each actuator is properly loaded, integrating electrical current sensing to determine the load carried by each actuator
Implementation Method 2
temperature sensors to ensure each actuator is properly loaded
Implementation Method 3
uses a method with a microprocessor based controller that controls electrical current supplied to the electric actuator(s) to control extension and retraction of the actuator(s)
Data Source
AI summary
An object 10 includes an electric actuator system 11 and a method 12. The object 10 may be a vehicle that includes wheels 18-21. The system 11 and method 12 include microprocessor based controllers 32, 33 and 37, electric actuators 22-25, 38 and 39, and a user interface 34 with an integrated level sensor and temperature sensor. The system 11 and method 12 operate to automatically or manually move the vehicle 10 from a not level attitude to a level attitude when the vehicle 10 is parked. The system 11 and method 12 in a preferred embodiment (FIGS. 4-6) may be configured to utilize any number of substantially identical controllers and actuators. The system 11 and method 12 sense the load carried by each actuator, to assure the wheels of the vehicle are not carrying more than a desired amount of the load when the vehicle is parked.