Decentralized Hydraulic Boom Control for Faster Manipulator Response
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing manipulators for truck-mounted concrete pumps experience delays and non-uniform movement due to long hydraulic control line lengths and dynamic behavior of lowering brake valves, leading to impaired response behavior and accuracy, especially at low pivoting speeds.
Innovation Solution
The implementation of electrically controlled proportional valves directly on each drive unit, connected to hydraulic working lines, allows for reduced line lengths and improved response behavior, with stepper motor control and hydraulically pilot-operated check valves for enhanced dynamic performance and load-holding functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a central mast control block with long hydraulic control lines is used, then the system structure is simplified and easier to implement, but the response behavior deteriorates due to noticeable delays between control lever adjustment and drive unit movement
Solution Approach 1:
The patent divides the centralized control system into decentralized control units, with each drive unit having its own control valve directly integrated. This segmentation eliminates long hydraulic control lines by placing the control function at the point of actuation, thereby resolving the contradiction between structural simplicity and response speed.
Solution Approach 2:
The patent transitions from a centralized control architecture to a distributed control architecture, changing the spatial dimension of control element placement. By moving control valves from a central location to individual drive units, the system achieves both structural modularity and reduced control line lengths.
2Ease of manufacture
If lowering brake valves with long control lines are used, then the system is easier to implement centrally, but the movement accuracy deteriorates due to non-uniform and undefined movement at low speeds
Solution Approach 1:
The patent segments the control function from the central block to individual drive units, eliminating the problematic long control lines and lowering brake valves. Each drive unit becomes an independent control module with integrated valves, achieving both ease of implementation and precise movement control.
Solution Approach 2:
The patent replaces the mechanical lowering brake valve system with an electro-hydraulic proportional valve system. This substitution eliminates the dynamic behavior issues of mechanical brakes at low speeds while maintaining ease of implementation through standardized electro-hydraulic components.
3Device complexity
If proportional valves are arranged centrally in a mast control block, then the system structure is simpler to implement, but the response behavior deteriorates due to long working lines between valves and drive units
Solution Approach 1:
The patent segments the hydraulic control system into distributed control units at each drive location. By placing proportional valves directly on or near each drive unit, the system eliminates long working lines while maintaining structural organization through modular design.
Solution Approach 2:
The patent introduces local control units as intermediaries between the central control system and individual drive units. These local units house the proportional valves close to the drive mechanisms, serving as intermediaries that reduce hydraulic line lengths while maintaining system-wide coordination.
4Ease of manufacture
If long hydraulic working lines are used between control valves and drive units, then the system is easier to install centrally, but the agility and dynamic performance deteriorate
Solution Approach 1:
The patent segments the hydraulic system into modular drive units with integrated control valves. This segmentation reduces hydraulic line lengths to minimal local connections, significantly improving agility and dynamic response while maintaining installation ease through standardized modular components.
Solution Approach 2:
The patent optimizes the hydraulic system for dynamic performance by minimizing line lengths and placing control valves directly at drive units. This dynamic optimization enables faster response times and better agility while the modular design maintains installation simplicity.
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 configuration significantly reduces delays and improves the manipulator's agility and accuracy, ensuring precise movement control and vibration damping, even at low speeds, with weight savings and reduced installation space.
Implementation Method 1
each can be actuated by means of an electrically controlled proportional valve, which is connected to hydraulic working lines of the respective drive unit for its control
Implementation Method 2
at least one proportional valve can be controlled with a stepper motor
Implementation Method 3
with stepper motor control and hydraulically pilot-operated check valves for enhanced dynamic performance and load-holding functions
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a manipulator (1), in particular a large manipulator for truck-mounted concrete pumps, comprising an articulated boom (2) which can be folded out and which has a turntable (5) that can be rotated about a vertical axis (4) and a plurality of boom segments (6, 6a, 6b, 6c). The boom segments (6, 6a, 6b, 6c) can be pivoted to a limited degree about a respective articulation axis at articulation joints (7, 7a, 7b) relative to an adjacent boom segment (6, 6a, 6b, 6c) or relative to the turntable (5) by means of a respective drive assembly (11). The manipulator also comprises a remote control device (9), which has at least one control lever (8) that can be moved in different movement directions, and a control device (10) for actuating the drive assemblies (11). The aim of the invention is to provide a manipulator which allows a simple operation and an excellent response behavior. This is achieved in that the control unit (10) converts a travel command which indicates a desired movement of the boom tip (3) of the articulation boom or of an end tube attached to the boom tip into movement specifications for the drive assemblies (11), wherein the travel command can be generated by moving the control lever (8) in at least one movement direction. The drive assemblies (11) can be actuated by means of a respective electrically actuated proportional valve (12) which is connected to hydraulic working lines (13, 14) of the respective drive assembly (11) in order to actuate same, and at least one of the proportional valves (12) is arranged directly on the drive assemblies (11) to be controlled or in the immediate vicinity thereof.