Dump Cylinder Speed Control via Piston Position Feedback
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Solution Overview
Problem
Conventional hydraulic excavators lack precise control over the dump cylinder's position, leading to rapid extension or retraction, which causes component wear and premature failure due to high-speed movements.
Innovation Solution
Incorporating a position sensor within the dump cylinder to monitor the piston's position and an electronic controller that adjusts the speed of the dump cylinder using output signals from the sensor, implementing speed reduction functions like linear, logarithmic, or quadratic ramp-down to prevent excessive force on internal components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the dump cylinder operates at high speed to improve productivity, then the dump operation becomes faster and more efficient, but component wear increases and premature failure occurs due to forceful contact between internal components
Solution Approach 1:
The controller预先 determines the piston position using output signals from the position sensor before the piston reaches the end-of-travel position. Based on this preliminary position information, the controller proactively reduces hydraulic fluid flow to slow the piston down before impact occurs, preventing damage while maintaining high-speed operation for most of the stroke
Solution Approach 2:
The position sensor continuously provides output signals to the controller about the piston's location within the dump cylinder. The controller uses this feedback information to dynamically adjust the hydraulic fluid flow rate, reducing flow as the piston approaches the end-of-travel position to slow it down and prevent impact damage
2Loss of time
If the dump cylinder extends or retracts rapidly to reduce cycle time, then the productivity increases, but shock forces damage the internal components and reduce operational life
Solution Approach 1:
The controller预先 identifies when the piston is approaching the end-of-travel position using position sensor feedback, and proactively reduces hydraulic fluid flow to slow the piston down before it reaches the endpoint, preventing shock forces while maintaining rapid movement during the majority of the stroke
Solution Approach 2:
The controller dynamically changes the flow rate parameter of hydraulic fluid based on the piston position. By adjusting this parameter in real-time according to position feedback, the system achieves high-speed operation during most of the stroke while reducing speed near the endpoints to minimize shock forces
Data Source
AI summary
Embodiments described herein provide for the control of an industrial machine dump operation by monitoring a position of the piston within a dump cylinder. The position of the piston is determined using a sensor within the dump cylinder. The sensor generates and provides an output signal to a controller. Based the output signal from the sensor, the controller is configured to limit the travel of the dump cylinder during the dump operation to reduce wear on the dump cylinder (e.g., by preventing damage caused when the dump cylinder is extending or retracting rapidly and the internal cylinder components make forceful contact with the rod or cap end).