Concrete Pump Boom Tip Control With Sag Compensation
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Solution Overview
Problem
Existing large manipulators, such as truck-mounted concrete pumps, face challenges in accurately determining the position of boom segments due to limitations in rotary angle sensors and the complexity of accounting for elastic deformation and load variations, leading to inaccurate operation and increased development outlay.
Innovation Solution
Incorporating an inclination sensor at the last boom segment and a control unit that calculates elastic deformation by combining folding angles and inclination data, allowing for precise correction of sag and position estimation of boom segments, enabling simple and reliable operation through single-lever control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If rotary angle sensors are used to detect folding angles between boom segments, then the position of boom segments can be established, but elastic deformation causes measurement inaccuracy
Solution Approach 1:
The patent introduces an intermediary calculation process that uses the detected inclination of the boom tip as a reference point to back-calculate the elastic deformation of each boom segment. This intermediary approach allows the system to compensate for elastic deformation effects without requiring direct measurement of each segment's deformation, thereby maintaining measurement reliability while accounting for elastic effects.
Solution Approach 2:
The system implements feedback by using the inclination sensor data from the boom tip to continuously update the calculation of elastic deformation. This feedback loop allows the control unit to adjust position calculations in real-time based on actual elastic deformation occurring in the boom segments, improving measurement precision dynamically.
2Measurement precision
If direct measurement methods (laser, infrared, GPS) are used to determine boom segment position, then position accuracy can be improved, but the surrounding environment and cost make these methods unsuitable
Solution Approach 1:
The patent extracts only the essential measurement requirement - the inclination of the boom tip - and uses this single piece of data in combination with folding angle measurements to calculate all necessary position information. This extraction approach avoids the complexity of direct measurement methods while achieving sufficient accuracy for the application.
Solution Approach 2:
The patent replaces complex direct measurement systems (laser, infrared, GPS) with a simplified calculation-based system that uses basic sensor data (folding angles and boom tip inclination) combined with mathematical models to determine boom segment positions. This substitution reduces device complexity while maintaining operational accuracy.
3Measurement precision
If mathematical models are used to calculate elastic deformation, then position can be estimated, but model accuracy requirements increase development outlay
Solution Approach 1:
The patent changes the approach from requiring highly accurate complex mathematical models to using a simplified model that leverages the directly measured boom tip inclination as a key parameter. This parameter change allows the use of less complex mathematical relationships while maintaining sufficient accuracy for deformation calculation.
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 provides accurate and reliable control of boom segment positions, enhancing operational precision and reducing the complexity and cost associated with existing methods by using a single additional sensor and simplified mathematical models.
Implementation Method 1
an inclination sensor (9) arranged at the last boom segment (5c), which forms the boom tip (7), and wherein the control device (8d) is configured to approximately establish the elastic deformation of the folding boom (2) taking account of the folding angles (φ1, φ2, φ3, φ4) that were detected between all boom segments (5, 5a, 5b, 5c) and the turntable (4) and the inclination of the last boom segment (5c) that was detected by means of the inclination sensor (9)
Data Source
AI summary
A large manipulator including an extendable folding boom. The extendable boom includes a turntable that is rotatable about a vertical axis and boom segments pivotable at folding joints about folding axes in relation to an adjacent boom segment or the turntable via respective drive assemblies. The extendable boom further includes rotary angle sensors configured to detect folding angles between adjacent boom segments or between one of the boom segments and the adjacent turntable. The extendable boom further includes an inclination sensor arranged at a last of the boom segments forming a boom tip and a computing unit configured to establish an elastic deformation of the extendable folding boom based on the detected folding angles and the inclination of the last boom segment.