Excavation Machine Drive Control for Stable Power Under Variable Loads
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing excavation machines face challenges in efficiently managing power fluctuations due to varying material conditions, leading to engine stalling and inefficiencies in cutter drive systems, particularly with diesel engines, and mechanical and vibration issues with cutting tools.
Innovation Solution
Implementing an electric-mechanical transmission system with a motor controller that adjusts speed and torque independently of engine operation, combined with a control system that automatically adjusts the advancement system to maintain consistent power draw, and mechanical arrangements that isolate motors from vibrations and oscillations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the advancement drive system operates at high power to maximize production, then productivity increases, but the cutter drive system experiences power fluctuations and engine stalling due to varying material conditions
Solution Approach 1:
The control system continuously monitors the power output of the cutter drive system and adjusts the advancement drive system accordingly. When the cutter drive requires less power due to varying material conditions, the control system reduces advancement speed to maintain optimal power draw from the engine, preventing stalling while maximizing productivity.
Solution Approach 2:
The system dynamically adjusts the operating parameters of the advancement drive system based on real-time feedback from the cutter drive system. The control algorithm continuously varies the advancement speed to match the power requirements of the cutter drive, ensuring the engine operates at optimal load levels across varying material conditions.
2Force
If the cutter drive system increases power output to handle harder material, then cutting capability improves, but the engine operates inefficiently and may stall
Solution Approach 1:
The control system monitors the power output and load conditions of the cutter drive system in real-time. When harder material is encountered and the cutter drive requires increased power, the control system adjusts the advancement speed to maintain optimal engine loading, ensuring efficient energy utilization while providing sufficient cutting force.
Solution Approach 2:
The system changes the operating parameters of the advancement drive system based on the power requirements of the cutter drive. By continuously adjusting advancement speed in response to cutter drive power demands, the engine operates at optimal efficiency points across varying cutting conditions, maximizing energy utilization.
3Speed
If the advancement system speed is increased to improve productivity, then cutting speed increases, but power fluctuations cause mechanical stress and vibrations on the cutter drive system
Solution Approach 1:
The control system continuously monitors the power output of the cutter drive system and adjusts the advancement speed to maintain consistent power draw. This feedback mechanism smooths out power fluctuations and reduces mechanical stress and vibrations on the cutter drive system while maintaining high cutting speeds.
Solution Approach 2:
The system dynamically adjusts advancement speed based on real-time power requirements of the cutter drive. This dynamic control maintains optimal operating conditions, reducing mechanical stress and vibrations while preserving high cutting speeds through continuous adaptation to material conditions.
Data Source
AI summary
An excavation machine is provided. The excavation machine includes an excavation device and an excavation device drive system that powers the excavation device to move cutting tools, wherein the excavation device drive system includes an electric motor and a motor controller, wherein the motor controller is programmed to control the speed of the excavation device drive system. The motor controller sets the speed of the excavation device drive system at a predetermined excavation speed based on a predetermined target power, the predetermined target power being associated with a target torque generated by the electric motor. The speed of the excavation device drive system is set at a predetermined first excavation speed when a power transmitted to the electric motor is below the predetermined target power and at a predetermined second excavation speed to maintain the power transmitted to the electric motor at the predetermined target power.