Boom Control System for Concrete Distributing Device
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Solution Overview
Problem
Existing hydraulic systems for controlling the boom of concrete distributing devices face issues with motion track deviation during composite motion due to under-saturation of flow, leading to increased labor intensity and compromised operating efficiency and stability, as higher-loaded knuckle arms fail to achieve expected movement speeds.
Innovation Solution
A control system that calculates and adjusts the flow of the boom pump based on rotation speed and displacement, using electrical proportional control valves to ensure proportional reduction in movement speeds of actuating mechanisms, independent of load differences, thereby maintaining the intended motion track.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a load-sensitive hydraulic system with pressure compensation function is used to ensure simultaneous action of multiple actuating mechanisms, then the movement speeds can be regulated steplessly independent of load, but the flow is taken to meet the demand of knuckle arms that bear lower loads first, causing the speeds of knuckle arms that bear higher loads to be lower than expected
Solution Approach 1:
The control system calculates the actual flow output of the hydraulic pump in real-time based on rotation speed and displacement, compares it with the sum of theoretical flow demands of all actuating mechanisms, and dynamically adjusts control signals to electrical proportional control valves. This feedback mechanism ensures that when total demand exceeds pump capacity, the system proportionally reduces speeds of all actuating mechanisms while maintaining the intended motion track, rather than allowing lower-loaded mechanisms to consume available flow first.
Solution Approach 2:
The system transitions from a static load-sensitive hydraulic system to a dynamic control system that continuously monitors pump output and actuating mechanism demands. The electrical proportional control valves receive dynamically adjusted control signals based on real-time flow conditions, enabling the system to adaptively allocate hydraulic flow during composite motion of multiple knuckle arms.
2Productivity
If the sum of flows demanded by oil cylinders of all knuckle arms exceeds the maximum flow output from the pump, then flow under-saturation occurs, but the motion track of the boom end deviates from the expected track
Solution Approach 1:
The control system performs real-time feedback control by calculating the ratio between actual pump flow output and total theoretical flow demand of all actuating mechanisms. When flow under-saturation is detected (sum of demands exceeds pump capacity), the system proportionally adjusts control signals to all electrical proportional control valves, ensuring that the relative motion relationships among multiple knuckle arms are maintained and the boom end follows the intended motion track.
Solution Approach 2:
The control system calculates the theoretical flow demand and required control signals for all actuating mechanisms in advance based on the intended motion trajectory. By comparing these pre-calculated values with actual pump flow capacity, the system proactively adjusts control signals to prevent motion track deviation before it occurs, rather than correcting after deviation happens.
3Manufacturing precision
If an operator continually changes the openness of the operating handle to correct motion track deviation, then the motion track can be maintained, but the labor intensity is severely increased and operating efficiency is compromised
Solution Approach 1:
The control system automates the motion track correction process by continuously monitoring flow conditions and automatically adjusting control signals to electrical proportional control valves. The system performs the function that previously required continuous manual intervention by the operator, thereby eliminating the need for continual adjustment of the operating handle while maintaining accurate motion tracking.
Solution Approach 2:
The system replaces the mechanical manual control mechanism (operating handle) with an electrical control system that uses sensors, calculators, and electrical proportional control valves. This substitution transforms the manual mechanical adjustment process into an automated electrical control process, significantly reducing operator labor intensity while maintaining or improving motion track accuracy.
Data Source
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AI summary
Disclosed are a concrete distributing device and a control method, a control system and an electrical control system for composite motion of a boom thereof. The control method comprises the steps as follows: calculating the flow of a boom pump when an operating handle sends a command; according to the command sent by the operating handle, calculating theoretical demand flow of all actuating mechanisms of the boom and theoretical control signals of all electronic proportional control valves; comparing the total theoretical demand flow of the actuating mechanisms with the flow of the boom pump; providing the theoretical control signals to all the electronic proportional control valves when the flow of the boom pump is greater than or equal to the total theoretical demand flow of the actuating mechanisms, otherwise, providing actual control signals smaller than the theoretical control signals to all the electronic proportional control valves and reducing the movement speeds of all the actuating mechanisms proportionally. In this way, when undersaturation of system occurs to the composite motion of the boom, the movement speeds of all the actuating mechanisms are reduced proportionally independent of the load difference of the actuating mechanisms, thereby ensuring that the boom can move in a motion track expected by an operator.