Concrete Pump Piston Control via Sensor Feedback
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Solution Overview
Problem
Existing concrete pumping units experience noise, vibrations, mechanical stress, and inefficiencies due to abrupt piston movements and lack of precise control over piston position, leading to reduced lifespan and fluidity issues.
Innovation Solution
A pumping unit with sensors to monitor piston position, speed, and other operating conditions, allowing for continuous control and optimization of piston movements through an auxiliary hydraulic circuit, which intervenes to slow down and coordinate piston reversals, reducing noise and vibrations and improving fluidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If end-of-travel detectors are used to control piston inversion, then the pumping operation can be maintained, but noise and vibrations increase significantly
Solution Approach 1:
The sensor detects the piston position in advance before it reaches the end of travel, allowing the hydraulic command circuit to prepare for the inversion process ahead of time. This preliminary detection enables gradual speed reduction and controlled stopping, preventing abrupt movements that generate noise and vibrations.
Solution Approach 2:
The sensor provides continuous feedback on the piston position to the electronic control unit, which adjusts the hydraulic command in real-time. This feedback mechanism allows the system to monitor and control the piston speed throughout its travel, ensuring smooth deceleration and inversion while maintaining pumping continuity.
2Device complexity
If abrupt piston inversion is implemented, then the mechanical structure is simpler, but mechanical stress and component wear increase
Solution Approach 1:
The patent replaces the traditional mechanical end-of-travel detection system with an electronic sensor-based position detection system. This substitution allows for precise control of piston movement through electronic signals, enabling gradual deceleration and controlled inversion, which reduces mechanical stress and component wear while maintaining system reliability.
3Ease of operation
If end-of-travel detection is used, then piston inversion can be achieved, but precise position control is lost
Solution Approach 1:
The sensor continuously monitors the piston position throughout its entire travel, providing dynamic data to the electronic control unit. This enables the system to adaptively control the hydraulic command based on the actual piston position, achieving both smooth inversion and precise position control, and allowing for optimization of the pumping cycle timing.
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
The solution significantly reduces noise and vibrations, stabilizes engine revolutions, enhances pumping efficiency, and simplifies maintenance by enabling precise control and automatic phasing of pistons, ensuring consistent concrete delivery and extended equipment lifespan.
Implementation Method 1
at least a sensor member operatively associated to at least one of the cylinders in order to detect at different points one or more data relating to the operating condition of the pumping piston during the whole travel of its movement
Implementation Method 2
at least a hydraulic command circuit, or main circuit, operatively connected to both cylinders, and able to determine an alternate pumping movement of the pumping pistons
Data Source
Figure 1~2
AI summary
Pumping unit (10) for a machine to distribute concrete comprising: a pair of pistons (12, 13) provided with a relative pumping cylinder (22, 23) movable linearly for a determinate travel (S) to feed the concrete to a determinate circuit to distribute the concrete; and a hydraulic command circuit (11) operatively connected to both the pistons (12, 13), to determine an alternate pumping movement of the relative pumping cylinders (22, 23). The pumping unit (10) comprises at least a sensor member (15) operatively associated to at least one of the pistons (12, 13) in order to detect point-by -point one or more data relating to the operating condition of the pumping cylinder (22, 23) during its movement for the whole travel (S). The data comprise at least one of position, speed, stress and direction of movement of the relative piston (12, 13).