Dynamic Tensioner Locking for Track Systems
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Solution Overview
Problem
Existing track systems face issues with uneven load distribution and tension management during braking, leading to ratcheting, reduced efficiency, and premature wear, as well as inadequate compliance with safety regulations regarding immobilization and deceleration.
Innovation Solution
A dynamic tensioning system with a dynamic blocking tensioner device that uses an inertial valve to control fluid flow, allowing optimal track tensioning while blocking or limiting movement during braking events, and employing a solenoid valve for electronic control to maintain tension and prevent ratcheting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional passive tensioner using grease-filled cylinder and accumulator is used, then the track tension can be maintained during normal operation, but the tensioner cannot prevent track loosening and ratcheting during braking events
Solution Approach 1:
The tensioner system transitions from a passive static design to a dynamic active design by incorporating a valve assembly that responds to inertial forces during braking. The valve assembly includes a valve body with a flow passage and a blocking element that moves in response to directional forces, allowing the system to adapt its tensioning behavior based on operational conditions.
Solution Approach 2:
The system implements feedback through the valve assembly that detects braking events via inertial forces acting on the blocking element. When braking is detected, the blocking element obstructs fluid flow between the actuator and accumulator, providing automatic feedback control to maintain track tension without requiring external intervention.
2Ease of operation
If the idler wheel is allowed to move upward during braking, then the track can accommodate terrain variations, but the track tension decreases leading to ratcheting and wear
Solution Approach 1:
The valve assembly is designed to detect braking events before significant track loosening occurs. The blocking element responds to inertial forces by obstructing fluid flow, thereby preemptively preventing the idler wheel from moving upward and causing track ratcheting, rather than allowing the harmful effect to manifest and then correcting it.
Solution Approach 2:
The accumulator is designed to store sufficient fluid under pressure to maintain track tension during braking events. The fluid cushion in the accumulator provides beforehand cushioning by readying pressurized fluid to counteract the upward movement of the idler wheel, preventing track loosening before it occurs.
3Reliability
If the track tension is increased to prevent ratcheting during braking, then track stability improves, but power loss from excess friction increases
Solution Approach 1:
The system dynamically adjusts track tension based on operational conditions. During normal operation, the tensioner maintains optimal tension for terrain adaptation. During braking events, the valve assembly activates to increase tension only when needed, preventing both excessive friction during normal operation and track loosening during braking.
Solution Approach 2:
The system changes the tension parameter dynamically by controlling fluid flow between the actuator and accumulator. The valve assembly modulates the fluid pressure and flow rate, allowing the track tension to transition between different states (normal tension during operation, increased tension during braking) to optimize both energy efficiency and stability.
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 system effectively maintains optimal track tension, reduces wear, and enhances vehicle traction and mobility by preventing ratcheting and ensuring compliance with safety standards by dynamically adjusting tension based on directional forces.
Implementation Method 1
an inertial valve operatively connected to the fluid flow path as to impede or block the flow upon the occurrence of a directional or inertial force applied to the track system
Implementation Method 2
employing a solenoid valve for electronic control to maintain tension and prevent ratcheting
Implementation Method 3
A piston in the cylinder moves as grease is added or removed through a fitting. By it's motion, the piston move the sprocket or idler wheel relative to the track
Data Source
AI summary
A track system comprising a dynamic tensioning device located between an idler wheel and the support frame as to apply proper tension in the track. The dynamic tensioning device is adapted to block at its current length upon the occurrence of a determined condition. The dynamic tensioner is adapted to substantially maintain its length when an acceleration and or deceleration of the track system reaches a predetermined value. For instance, such characteristic is relevant in an event of emergency braking. A dynamic tensioner would become contracted and the tension in the endless track would become too low. A low tension could cause the endless track to ratchet.