Distributed Electrohydraulic Control for Concrete Pump Manipulator
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current electrohydraulic control circuits for large manipulators, such as truck-mounted concrete pumps, face issues with delayed response behavior, susceptibility to line breaks, and inability to adapt to dynamic operations due to central control blocks and pressure supply variability, leading to inefficient vibration damping and movement control.
Innovation Solution
An electrohydraulic control circuit with an electrically driven first valve and check valves controlled by an electronic unit, reducing line lengths and incorporating pressure sensors for adaptive pressure supply, along with sensors for deformation and orientation signals to enhance control precision and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a central control block is used to control individual segments, then individual segment control is achieved, but line lengths become very long (up to 70 m) causing delayed response behavior and increased susceptibility to line breaks
Solution Approach 1:
The control system is segmented into distributed control units, each responsible for specific segments of the manipulator. This eliminates the need for long centralized hydraulic lines while maintaining individual segment control capability. Each control unit is positioned close to the segments it controls, reducing line lengths and improving response time.
Solution Approach 2:
The control architecture transitions from a centralized hierarchical structure to a distributed network structure. This dimensional change in system organization allows control functions to be distributed across multiple locations, reducing the physical distance between control elements and improving system reliability.
2Stability of the object's composition
If lowering brake valves are used to prevent segment lowering, then segment position stability is improved, but response behavior deteriorates due to additional delays and frequent opening/closing during active regulation
Solution Approach 1:
The mechanical lowering brake valve system is replaced with an electrohydraulic control system that uses electronically controlled valves. This substitution eliminates the mechanical delay associated with brake valve opening/closing operations and allows for faster, more precise position control during active regulation while maintaining stability.
Solution Approach 2:
The control system transitions from static brake valve positioning to dynamic electrohydraulic control. The electronically controlled valves can respond rapidly to position changes and regulate segment movement in real-time, providing both stability and fast response behavior during active regulation.
3Object-generated harmful factors
If pressure sensors are used to determine vibrations, then vibration detection is achieved, but measurement precision is reduced because pressure sensors do not directly measure dynamic states and are influenced by non-ideal pressure supply
Solution Approach 1:
Instead of using pressure sensors that indirectly detect vibrations through pressure changes, the system uses accelerometers as direct measurement intermediaries. Accelerometers directly measure dynamic states and vibrations without being influenced by pressure supply variations, providing accurate vibration detection for active damping control.
4Device complexity
If electrohydraulic control circuits are used exclusively in hardware, then system simplicity is maintained, but adaptability is reduced preventing versatile use and operation-specific adaptation
Solution Approach 1:
The electrohydraulic control system incorporates programmable electronic control units that can be configured for different operating modes and applications. This universal design allows the same hardware platform to adapt to various operations through software programming, providing versatility while maintaining system simplicity through standardized components.
Solution Approach 2:
The control system transitions from fixed hardware configuration to dynamically reconfigurable electronic control. The programmable microprocessors and control algorithms can be adjusted in real-time to adapt to different operating conditions, enabling versatile use across multiple applications while maintaining a simple standardized hardware architecture.
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 provides a robust, adaptable, and efficient control system that minimizes vibrations and ensures precise movement control, improving response behavior and reducing costs by leveraging electronic control for versatile operation and fail-safe functions.
Implementation Method 1
hydraulic actuating elements, which actuating elements can be selectively operated electrohydraulically
Implementation Method 2
pressure sensors are provided, wherein a pressure sensor is mounted on a bottom-side end and on a rod-side end of each piston and the corresponding time-dependent measurement signal delivers the pressure difference
Implementation Method 3
the release of the check valves is controlled by an electronic control unit separate from the first valve and the check valves
Data Source
AI summary
A regulation system for controlling the orientation of a segment (5.3) of a manipulator, in particular of a large manipulator for truck-mounted concrete pumps, wherein the segment (5.3) is connected to a base (5.4) or a preceding segment (5.3) of the manipulator via a joint (5.5) and can be pivoted at the joint (5.5) relative to the base (5.4) or the preceding segment (5.3) about at least one axis of rotation by means of at least one actuating member (5.6), preferably a hydraulic actuating element,characterized in that the regulation system at least comprises:a first sensor (4.1), which is arranged on a segment (5.3) attached to the joint (5.5) and delivers a first measurement signal—referred to as a “deformation signal”—corresponding to a deformation of the segment (5.3),a second sensor (4.2, 4.3), which delivers a second measurement signal—referred to as an “orientation signal”—corresponding to the spatial orientation of the segment (5.3) attached to the joint (5.5), andat least one actuating element (5.6) associated with the joint (5.5);and is designed to process the deformation signal and the orientation signal as input variables and to determine from these, under consideration of a target orientation of the segment (5.3) associated with the joint (5.5), an actuating signal, which is fed to the associated actuating element (5.6).