Electric Actuator Force Limiting for Power Machine Load Protection

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Solution Overview

Problem

Conventional hydraulic systems in excavators and other power machines face challenges in managing excessive loads on actuators and structures due to external forces, which can lead to deformation or damage, especially with the transition to electric actuators.

Innovation Solution

Implementing a control system with electronic processors to monitor and manage electric actuators, emulating hydraulic port relief valves by controlling electric actuators to prevent excessive forces, using current monitoring and geometric relationships to adjust actuator motion and position.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If electric actuators are used in power machines, then the machine can perform complex operations with precise control, but the actuators and structures are vulnerable to excessive loads and deformation

Engineering Contradiction:

Improvecomplex operations capabilityVSAvoidresistance to excessive loads

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The control system proactively monitors forces on electric actuators and implements protective measures before damage occurs. When a force threshold is exceeded, the system automatically adjusts actuator operation to reduce the force, preventing deformation or damage to the actuator and surrounding structures.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The system continuously monitors the force experienced by electric actuators during operation and uses this feedback to dynamically adjust actuator commands. When excessive force is detected, the control system modifies the actuator operation to reduce force while maintaining operational functionality, enabling both complex operations and protection.

Inventive Principle:

Principle #23Feedback

2Reliability

If force monitoring and control systems are implemented to protect actuators, then actuator protection is improved, but the system complexity increases

Engineering Contradiction:

Improveactuator protectionVSAvoidcontrol system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The control system performs self-monitoring and self-protection by automatically detecting excessive forces on actuators and adjusting its own commands to prevent damage. The system uses its existing control infrastructure to monitor actuator forces and implement protective measures without requiring separate dedicated protection hardware, reducing overall system complexity.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system dynamically changes operational parameters of electric actuators based on real-time force conditions. By adjusting actuator commands in response to force threshold exceedances, the system achieves protection through parameter modulation rather than through complex structural modifications or additional protective mechanisms.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20260078566A1Force-based control of electrically actuated power machines

Publication Date: 2026.03.19 DOOSAN BOBCAT NORTH AMERICA INC

AI summary

Force-based control for electrically actuated power machines. One system may include one or more electronic processors in electrical communication with an electric actuator of the electric power machine. The one or more electronic processors may be configured to receive data for an electric power machine while the electric power machine is performing an operation and determine, based on the data, a force of the electric power machine. The one or more electronic processors may be configured to, responsive to the force exceeding a threshold, control the electric power machine to enforce a force limit.