Adaptive Hydraulic Brake Unit for Load-Stable Mobile Machines
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Solution Overview
Problem
Mobile work machines, such as dumpers, often experience stability issues due to excessive braking force when unloaded, leading to potential tipping and safety concerns, as their braking systems are not adapted to varying loads and do not include advanced brake assistance systems like ABS or ESP.
Innovation Solution
A mobile work machine equipped with a hydraulic or electronic brake sensor that detects load weight and braking acceleration, allowing for adaptive braking control through a pressure relief valve and sensor actuator, which adjusts the maximum braking force based on the actual load, thereby preventing excessive deceleration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed pressure limiting valve is used in the braking system, then the fully loaded machine achieves the legally required maximum deceleration, but the empty machine experiences excessive deceleration that can cause tipping
Solution Approach 1:
The pressure limiting valve is replaced by a sensor actuator that dynamically adjusts the maximum brake pressure based on real-time load detection. The brake sensor detects weight force or payload, and the control unit adjusts the pressure limiting value accordingly, transitioning from a fixed static system to a dynamic adaptive system that prevents both insufficient braking when loaded and excessive braking when empty.
Solution Approach 2:
A brake sensor (weight force sensor or acceleration sensor) is introduced to detect the actual load or braking acceleration, creating a feedback loop. The control unit receives this sensor signal and adjusts the pressure limiting value in real-time, enabling the system to respond to changing load conditions and maintain optimal braking performance across all operating states.
2Productivity
If the maximum brake pressure is limited for fully loaded machines, then legal deceleration requirements are met, but the braking force remains constant regardless of actual load, causing proportional increase in deceleration as load decreases
Solution Approach 1:
The pressure limiting value is changed from a fixed parameter to a variable parameter that depends on the detected load. The control unit adjusts the maximum brake pressure parameter based on sensor feedback, allowing the braking system to adapt its performance characteristics to match the actual operating conditions, thereby achieving both consistent braking performance and load adaptability.
Solution Approach 2:
The braking system becomes self-regulating by using the brake sensor to automatically detect load conditions and adjust pressure limiting without driver intervention. The system serves itself by monitoring its own operating state and making appropriate adjustments to maintain optimal performance across varying load conditions.
3Ease of operation
If a pressure regulating valve with fixed pressure setting is used, then maximum braking force is limited to prevent excessive deceleration when loaded, but the system cannot adapt to varying physical characteristics of the driver or changing load conditions
Solution Approach 1:
The mechanical pressure regulating valve with fixed setting is replaced by an electronic control system comprising a brake sensor, control unit, and sensor actuator. This substitution transitions from a purely mechanical system to an electromechanical system that can process sensor signals and dynamically adjust braking parameters, enabling adaptation to varying driver characteristics and load conditions while maintaining ease of operation through automatic control.
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 solution enhances braking safety and comfort by ensuring stable deceleration across varying loads, reducing the risk of tipping and improving overall machine stability.
Implementation Method 1
the brake sensor is designed as a weight force sensor for detecting a weight force and/or payload of the working tool
Implementation Method 2
as an acceleration sensor for detecting a braking acceleration of the working machine
Implementation Method 3
the brake unit is designed as a hydraulic brake unit comprising at least one brake fluid, wherein at least one brake pedal is provided for manual actuation by an operator and for pressurizing the brake fluid
Data Source
Figure 1a~2
Figure 3~4b
AI summary
A mobile working machine (1) is provided with a vehicle frame (2) and with a drive unit for driving at least one drive wheel (4) rotatable about a drive axis, wherein at least one working tool (3), such as e.g.a recess (3) or the like, and/or a tool holding device for holding the working tool (3) is provided, wherein at least one brake unit comprising at least one brake element is provided for braking the at least one drive wheel (4), wherein the brake unit is designed as a hydraulic brake unit comprising at least one brake fluid, wherein at least one brake pedal is provided for manual actuation by an operator and for pressurizing the brake fluid, wherein the brake unit comprises at least one pressure limiting valve for limiting a maximum pressure of the brake fluid, which at least partially improves the disadvantages of the prior art, in particular to realize an improved and/or cost-effective brake system.According to the invention, this is achieved by providing at least one brake sensor (9) for detecting a brake parameter and by designing the brake sensor as a weight force sensor for detecting a weight force and/or payload of the working tool (3) or as an acceleration sensor for detecting a braking acceleration of the working machine (1).