Hydraulic Breaker Stepless Stroke Control via Vibration Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional hydraulic breakers face inefficiencies and increased wear due to excessive impact energy during idle blows, as they lack precise control over hydraulic pressure and stroke length, leading to damage and reduced operational lifespan.
Innovation Solution
A stepless variable auto stroke hydraulic breaker system that employs a vibration sensor to detect rock-breaking vibrations, converting them into signals to automatically adjust the piston stroke from short to long and vice versa, using a transmitter, receiver, and microcontroller unit to optimize energy usage and reduce impact energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the hydraulic breaker operates continuously without stroke adjustment, then productivity is maintained, but impact energy is wasted during idle blows causing damage to components
Solution Approach 1:
The hydraulic breaker employs a stepless variable stroke mechanism that dynamically adjusts the piston stroke length based on real-time vibration feedback. When the chisel is in contact with rock (detected by vibration frequency), the stroke is extended to maximize breaking efficiency. When idle (no vibration), the stroke is reduced to minimize energy waste and impact damage. This dynamic adaptation resolves the contradiction between maintaining productivity and reducing energy loss.
Solution Approach 2:
The system incorporates vibration sensors that continuously monitor the vibration frequency generated by the chisel during operation. This feedback signal is processed by a controller that automatically adjusts the hydraulic valve to modify the piston stroke length. The feedback loop ensures the breaker operates at optimal stroke only when rock breaking is actually occurring, eliminating idle blows and their associated energy waste and damage risks.
2Productivity
If the piston stroke is extended to increase breaking power, then productivity improves, but the risk of damage from idle blows increases
Solution Approach 1:
The system dynamically varies the piston stroke length based on operational conditions. During active rock breaking, the full extended stroke provides maximum breaking power. During idle conditions, the stroke is automatically reduced, eliminating high-impact idle blows that cause component damage. This dynamic stroke adjustment maintains reliability while preserving productivity during actual breaking operations.
Solution Approach 2:
Vibration sensors provide real-time feedback on whether the chisel is in contact with rock. The controller uses this feedback to automatically adjust the hydraulic valve, extending the stroke only when vibration indicates active breaking. This feedback-controlled stroke adjustment prevents damage from idle blows while maintaining high breaking power during actual operation, resolving the reliability-productivity contradiction.
3Productivity
If the hydraulic pressure is increased to improve breaking performance, then productivity increases, but the risk of damage from pressure gradients and cavitation increases
Solution Approach 1:
The pressure accumulator is pre-charged with hydraulic fluid at a predetermined pressure before operation. This preliminary action ensures that when the piston requires high pressure for breaking, the accumulator can immediately supply pressurized fluid without creating dangerous pressure gradients or cavitation. The pre-charged accumulator acts as a buffer, maintaining system reliability while enabling high-performance breaking operations.
Solution Approach 2:
The system dynamically controls hydraulic pressure delivery through a variable stroke mechanism regulated by vibration feedback. High pressure is applied only when and where needed during actual breaking operations. During idle conditions, pressure is reduced, preventing the accumulation of dangerous pressure gradients and cavitation risks. This dynamic pressure management maintains breaking performance while ensuring hydraulic system safety.
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 system enhances work efficiency by dynamically adjusting piston strokes based on vibration frequency, reducing idle blow impact energy and extending the hydraulic breaker's lifespan by optimizing energy application.
Implementation Method 1
a vibration sensor configured to detect vibrations generated when a chisel breaks rocks and converts the detected vibrations into signals
Data Source
AI summary
Provided is a stepless variable auto stroke hydraulic breaker system capable of reducing impact energy reflected in the event of an idle blow by detecting a frequency of vibrations generated when a chisel breaks objects such as bedrocks using a vibration sensor, operating according to a short stroke if the frequency of vibrations does not exceed a preset frequency, and automatically switching the short stroke into a long stroke if the frequency of vibrations exceeds the preset frequency. The breaker system includes a vibration sensor configured to detect vibrations generated when a chisel breaks rocks, a transmitter provided with the vibration sensor and configured to transmit signals generated from the vibration sensor, a receiver configured to receive the signals transmitted from the transmitter, and a stepless variable auto stroke hydraulic breaker controlled by a reception micro controller unit (MCU) of the receiver.