Characteristic Curve Analysis for Component State Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing systems for controlling hydraulic components in working devices like cranes and excavators rely on manually set characteristic curves, leading to unnecessary maintenance and downtime due to infrequent component replacements, which can occur either too early or too late, resulting in high costs and reduced availability.
Innovation Solution
A system that compares active and inactive characteristic curves to assess the condition of components, allowing for timely maintenance and reducing unnecessary replacements by determining a control variable based on a target variable related to the movement of a drivable element, enabling proactive maintenance planning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If components are replaced or serviced after a predetermined time interval, then maintenance is performed regularly, but unnecessary component changes and maintenance work occur when components are not yet in need of replacement
Solution Approach 1:
The system changes the maintenance approach from time-based to condition-based by monitoring characteristic curves. Instead of replacing components at fixed intervals, the system detects actual component state through deviations in characteristic curves, allowing maintenance only when truly needed.
Solution Approach 2:
The patent replaces manual inspection and time-based scheduling with automated electronic monitoring and analysis systems. The control unit automatically compares characteristic curves and detects component state, substituting mechanical/time-based maintenance with intelligent sensor-based monitoring.
2Productivity
If components are replaced only after failure, then unnecessary maintenance is avoided, but unplanned downtime occurs resulting in high follow-up costs
Solution Approach 1:
The system performs preliminary detection of component degradation by monitoring characteristic curve deviations before complete failure occurs. This allows maintenance to be planned in advance rather than reacting to sudden failures, enabling proactive rather than reactive maintenance scheduling.
Solution Approach 2:
The system continuously monitors characteristic curves and provides feedback on component health status. The control unit compares actual characteristic curves with reference values and generates maintenance recommendations based on detected deviations, creating a closed-loop feedback system for predictive maintenance.
3Measurement precision
If characteristic curves are manually set or adjusted in the factory or on the test bench, then initial calibration is performed, but frequent manual adjustments are needed after component changes or long operation periods
Solution Approach 1:
The system enables self-service maintenance by automatically detecting component state through characteristic curve monitoring. The control unit autonomously compares current characteristic curves with reference values and determines when maintenance is needed, eliminating the need for manual inspection and adjustment by operators.
Solution Approach 2:
Manual characteristic curve adjustment is replaced with automated electronic monitoring and comparison systems. The control unit automatically detects deviations and triggers maintenance alerts, substituting manual mechanical adjustment with intelligent automated detection.
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a system for detecting the state of a component of a working device, comprising a working device, in particular a crane or excavator, a memory connected to the control unit, and an analysis means connected to the control unit. The working device has at least one element movable by a drive and a control unit by means of which the drive can be controlled. At least one active characteristic curve for controlling the drive of the working device is stored in the memory. According to the invention, the control unit is configured to determine a control variable for controlling the drive based on an active characteristic curve, depending on a target value relating to the movement of the driven element of the working device.Furthermore, the analytical instrument is designed to compare an active characteristic curve with an inactive characteristic curve and, based on this comparison, to infer the state of a component of the working device. The invention further relates to such a working device and a method for state detection of a component of such a working device.