Mobile Concrete Pump Stabilization Control via Dynamic Load Torque
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Solution Overview
Problem
Existing mobile concrete pumps lack effective real-time stabilization control, particularly in uneven terrain, which can lead to instability and potential tipping or overload, as they rely on static center of gravity calculations and limited safety coefficients without considering dynamic load torque and force distributions.
Innovation Solution
The solution involves real-time calculation of load torque and vertical/horizontal forces in the mast arm and support legs using sensors, including pressure sensors, rotational angle sensors, and inclination sensors to determine the actual stability reserve and predict the impact of concrete filling on stability, enabling safe operation beyond typical inclination limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If static center of gravity calculations and safety coefficients are used for stabilization control, then device complexity is reduced, but real-time stability monitoring precision deteriorates
Solution Approach 1:
The patent transitions from static center of gravity calculations to dynamic real-time stability control by continuously calculating load torque and support leg forces based on current mast arm position, concrete weight, and vehicle inclination. The control unit updates stability assessments dynamically during operation, allowing the system to adapt to changing loads and terrain conditions while maintaining manageable complexity through structured calculation methods.
Solution Approach 2:
The system implements feedback by continuously monitoring mast arm position via sensors, calculating current load torque and support leg forces, and using this information to determine actual stability reserve. This feedback loop enables real-time stability monitoring that adjusts to actual operating conditions rather than relying on predetermined static calculations.
2Measurement precision
If real-time calculation of load torque and support leg forces is implemented, then stability monitoring precision is improved, but device complexity increases
Solution Approach 1:
The control unit serves multiple functions: it controls mast arm positioning, calculates load torque, determines support leg forces, assesses stability reserve, and predicts the impact of concrete filling. By consolidating these functions in a single control unit rather than separate systems, the patent achieves high stability monitoring precision while managing overall device complexity through functional integration.
Solution Approach 2:
The system uses its own sensors and calculation capabilities to self-assess stability without requiring external monitoring equipment. The control unit automatically calculates load torque and support leg forces based on data from existing mast arm position sensors and concrete weight inputs, enabling the system to monitor its own stability state without adding separate complex monitoring infrastructure.
3Productivity
If the permissible working range is extended to increased inclinations, then productivity is improved, but operational safety deteriorates
Solution Approach 1:
The system provides continuous feedback on actual stability reserve and issues warnings when approaching critical instability thresholds. This feedback mechanism allows the system to extend working range to increased inclinations while maintaining safety by alerting operators to dangerous conditions, enabling informed decisions about whether to continue operation or adjust positioning.
Solution Approach 2:
The control unit calculates and predicts the impact of concrete filling on stability before pumping operations begin. By performing preliminary stability assessment and warning operators in advance about potential instability from added concrete weight, the system enables productive operation at increased inclinations while preventing dangerous situations through提前 warning.
Data Source
AI summary
The invention relates to a mobile concrete pump (10) having a chassis (12) which has extendable supporting legs (14), and a concrete distributor mast (18), which is arranged on a slewing mechanism (16) of the chassis (12) such that the concrete distributor mast can be slewed and the inclination thereof can be adjusted by means of an actuating cylinder (22), and which comprises multiple pivotable mast arms (20), and a computing unit for carrying out a stabilization calculation by using the vertical and/or horizontal forces on at least two supporting legs (14), and having a control device which is configured, depending on stability check, to delimit a slewing movement on the slewing mechanism (16) and/or a pivoting movement of at least one mast arm (20.1, 20.2 20.3) and/or the initiation of a pumping operation.