Adaptive Load Compensation for Industrial Machines
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Solution Overview
Problem
Industrial machines, such as electric rope shovels and draglines, face stresses and strains due to over-loaded conditions caused by increased material weight from factors like rain or snow, leading to potential loss of control and reduced operational life.
Innovation Solution
A control system that uses sensors to monitor and compare the suspended load of the machine to threshold values, dynamically adjusting speed and force parameters to mitigate these stresses, including modifying speed limits and force applications based on instantaneous or average load conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the industrial machine operates under over-loaded conditions, then the productivity increases, but the machine experiences additional stresses and strains that can cause damage
Solution Approach 1:
The control system dynamically adjusts operating parameters (speed limits, force applications) based on real-time load conditions detected by sensors. When over-load conditions are detected, the system modifies parameters adaptively rather than using fixed limits, allowing the machine to operate safely under varying load conditions while maintaining productivity when possible
Solution Approach 2:
The system continuously monitors load conditions using sensors and feeds this information back to the controller. The controller compares actual load to threshold values and automatically adjusts operating parameters in response, creating a closed-loop control system that prevents structural damage while optimizing productivity
2Productivity
If the industrial machine operates under over-loaded conditions, then the productivity increases, but the control capability is reduced due to increased inertia
Solution Approach 1:
The system dynamically modifies speed parameters and force applications based on detected load conditions. When over-load conditions are present, the control system adjusts parameters to maintain adequate control capability despite increased inertia, preventing loss of control while allowing continued operation
Solution Approach 2:
The controller changes operating parameters (speed limits, force magnitudes) based on load conditions. By modifying these parameters adaptively, the system maintains control capability under over-loaded conditions where increased inertia would otherwise reduce ease of operation
Data Source
AI summary
An industrial machine that includes a dipper, a crowd actuation device, a hoist actuation device, a swing actuation device, one or more sensors, and a controller. The one or more sensors generate one or more signals related to a load within the dipper. The one or more signals are received by the controller. The controller determines, based on the one or more signals, whether the industrial machine is operating in an over-loaded condition by comparing a suspended load to a suspended load threshold value. If the suspended load is greater or equal to the suspended load threshold value, the controller takes an action to control the industrial machine. The action taken by the controller can include increasing, decreasing, or otherwise modifying a speed parameter or speed limit, increasing, decreasing, or otherwise modifying a force parameter, etc.