Clutch Controller for Rapid Onset Overload Prediction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Machinery is prone to damage from rapid onset machine overload events, such as jams, which can cause severe torque spikes and abrupt changes in momentum, leading to potential engine stall and damage to the driving engine, driven machinery, or coupling assembly.
Innovation Solution
A computerized system that predicts and actively disengages the clutch using algorithms based on measured parameters like engine speed, torque, and rotational displacement to prevent engine stall and damage by disengaging the clutch before an overload event causes failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical reaction clutch release is used to protect against overload, then damage to engine and machinery is prevented, but the response time is delayed and cannot detect rapid onset overload events in time
Solution Approach 1:
The system performs preliminary action by continuously monitoring engine parameters (speed, torque, power) and using predictive algorithms to anticipate upcoming overload events before they occur. This allows the clutch to be disengaged proactively rather than reactively, preventing damage before it happens while maintaining timely response to rapid onset events.
Solution Approach 2:
The system implements feedback by continuously measuring engine parameters, comparing them against predicted values using algorithms, and automatically triggering clutch disengagement when deviations indicate an impending overload event. This closed-loop feedback system enables real-time detection and response to both gradual and rapid onset overload conditions.
2Reliability
If the clutch is disengaged frequently to prevent overload damage, then engine and machinery are protected, but operational downtime increases
Solution Approach 1:
By predicting overload events before they occur, the system allows operators to prepare for controlled shutdowns rather than experiencing sudden, unplanned failures. This preliminary warning enables scheduling maintenance during convenient times rather than during disruptive emergency stoppages, reducing overall operational downtime.
Solution Approach 2:
The system provides self-service by automatically detecting and responding to overload conditions without requiring constant operator monitoring or intervention. The automated clutch disengagement and system recovery processes minimize the need for manual intervention, reducing downtime associated with operator response and manual reset procedures.
3Reliability
If clutch friction pack is allowed to cool down to prevent damage, then overheating is avoided, but cooling time extends operational downtime
Solution Approach 1:
The system takes preliminary action by detecting impending overload events and disengaging the clutch before the friction pack reaches dangerous temperature levels. This preventive approach eliminates the need for extended cooling periods, as the clutch is protected from overheating in the first place rather than requiring post-event cooling time.
Solution Approach 2:
The system rushes through the protective disengagement process by quickly detecting overload conditions and immediately disengaging the clutch, minimizing the time the friction pack is subjected to excessive heat. This rapid response prevents thermal damage while reducing the duration of protective cooling periods needed.
Data Source
AI summary
A clutch controller provides protective disengagement of a clutch between an engine and driven machinery to prevent engine failure due to rapid onset overload. Sensor signals of measured parameters are used by the controller to determine potential engine failure. Multiple, successive sensor signals and elapsed times are assessed during which the current sensor signal value and the scaled rate of change in signal values is compared against a predefined amount. The clutch controller sends a clutch disengagement signal if a calculation result is indicative of imminent failure.