Down-force Control for Articulating Work Machine Arms
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Solution Overview
Problem
Existing systems for controlling downward force on work tools in work machines, such as excavators, are inadequate in maintaining the force within an acceptable range, especially when operated by an operator or used with tools other than a bucket tip, leading to potential tool damage and reduced job quality.
Innovation Solution
A computer-implemented method and control system within a work machine that receives tool data and force data, calculates the down force on the work tool, and generates an alert or adjusts the action of the work tool to maintain the down force within an acceptable range, ensuring consistent operation and protecting equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If down force control is implemented using existing systems, then some force regulation is achieved, but the force cannot be maintained within an acceptable range leading to tool damage and reduced job quality
Solution Approach 1:
The system continuously monitors down force through sensors and provides real-time feedback to the operator via display alerts when force exceeds acceptable ranges. This closed-loop feedback mechanism enables the operator to adjust controls to maintain force within acceptable ranges, preventing tool damage while ensuring consistent job quality.
Solution Approach 2:
The control system acts as an intermediary between the operator and the work tool, inserting a layer of monitoring and guidance. The system measures actual down force, compares it against acceptable ranges, and communicates this information to the operator, enabling informed adjustments without requiring direct operator knowledge of complex force dynamics.
2Adaptability or versatility
If manual operation of the linkage is used, then operator flexibility is maintained, but down force varies outside acceptable ranges causing potential tool damage
Solution Approach 1:
The system preserves manual operation while adding real-time down force monitoring and feedback. Sensors continuously measure force and provide alerts to the operator when force exceeds acceptable ranges, enabling the operator to maintain flexibility in controlling the linkage while ensuring force consistency through informed adjustments.
Solution Approach 2:
The system enables the operator to self-regulate down force by providing clear feedback about actual force levels. The operator uses the displayed information to autonomously adjust controls and maintain force within acceptable ranges, combining system monitoring with human judgment and adaptability.
3Device complexity
If no down force monitoring is implemented, then system complexity is reduced, but tool damage from dry-fire or overload conditions occurs
Solution Approach 1:
The system adds minimal monitoring complexity by using existing sensors to measure down force and providing simple feedback through the operator display. This straightforward feedback mechanism alerts the operator to unsafe force levels without requiring complex control algorithms, achieving equipment protection with relatively simple system additions.
Solution Approach 2:
The control system serves as an intermediary monitoring layer that sits between the existing linkage controls and the work tool. It uses available sensor data to assess down force and communicates risk levels to the operator, adding protection capability without fundamentally redesigning the complex hydraulic linkage system.
Data Source
AI summary
A work machine, such as an excavator or a backhoe, has a linkage of articulating arms for maneuvering a changeable work tool. Position and motion sensors and force sensors within the linkage provide data for a controller to determine a location of the work tool and down force applied from the linkage onto the work tool during a job. Based on characteristics of the work tool, an acceptable range of down force applied by the linkage may be assigned. If down force reaches an outer bound of the acceptable range during the job, the controller may generate an alert for the operator or adjust action by the work tool to maintain the down force within the acceptable range. Depending on the work tool and job, the down-force control can help improve work quality and guard against tool damage from dry-fire or overload conditions.