Excavator Bucket Door Brake Test Bench Using Pendulum Dynamics
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Solution Overview
Problem
Current hydraulic test benches for evaluating brake performance on excavator or electric shovel bucket doors fail to accurately simulate the high-speed and variable load conditions, leading to inadequate representation of real operating conditions and high testing costs.
Innovation Solution
A test bench that utilizes a pendulum mechanism with a known mass to store potential energy by inclining it above a horizontal reference level, transforming into kinetic energy to simulate the opening and closing movements of bucket doors, allowing for more realistic load application and adjustable counterweights to mimic different operating conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a hydraulic cylinder is used to apply a linear load at constant speed, then the testing setup is simple, but the simulation of bucket door movement is inaccurate
Solution Approach 1:
The patent applies the dynamics principle by replacing the static linear hydraulic cylinder system with a dynamic pendulum mechanism. The pendulum arm rotates about a pivot point, naturally producing variable speed and variable force characteristics that match the actual bucket door movement pattern. This dynamic system automatically generates the required motion profile without complex control systems.
Solution Approach 2:
The patent utilizes the curved motion path of the pendulum arm to simulate the arc-shaped movement of the bucket door. The pendulum's circular trajectory naturally reproduces the geometric characteristics of the door's opening and closing motion, providing accurate simulation of both the path and the variable speed profile.
2Ease of manufacture
If a hydraulic cylinder is used to simulate brake operation, then the test bench is cost-effective, but the high-speed and high-load conditions cannot be properly replicated
Solution Approach 1:
The patent employs the counterweight principle by using a mass attached to the pendulum arm to represent the bucket door load. This mass creates the necessary gravitational force that provides both the load and the accelerating effect during the pendulum's swing, enabling the system to replicate high-speed and high-load conditions without requiring equally expensive hydraulic systems.
Solution Approach 2:
The patent applies preliminary action by positioning the mass at a predetermined height before releasing it. This initial potential energy storage allows the system to generate the required kinetic energy and force during the test, enabling accurate simulation of high-speed brake operation conditions.
3Measurement precision
If a pendulum mechanism is used to simulate bucket door movement, then the simulation accuracy is improved, but the device complexity increases
Solution Approach 1:
The patent applies the self-service principle by designing a pendulum mechanism that automatically generates the required motion profile through its own gravitational force. The system uses the mass's weight to create both the driving force and the variable speed characteristics, eliminating the need for external power sources or complex control systems to achieve accurate simulation.
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
This solution enables more accurate simulation of real operating conditions, allowing for the evaluation of brake performance under various loads and speeds, reducing testing costs and improving the representation of bucket door movements.
Implementation Method 1
The test bench works through the potential energy stored by bringing a known mass up to a certain inclination, above a horizontal reference level
Implementation Method 2
transforming into kinetic energy to simulate the opening and closing movements of bucket doors
Implementation Method 3
A pendulum mechanism with a known mass to store potential energy by inclining it above a horizontal reference level
Data Source
AI summary
A test bench to evaluate the operation of a brake or shock absorber for bucket doors of excavators or electric shovels that allows simulating real operating conditions of the bucket doors, which includes a brake support that allows installing and fixing the brake to be evaluated, said brake comprising, a body with an axis that is connected to the end of an arm in a pivotal manner and its other end is used for connection with the bucket door; a pendulum to simulate the loads received by the brake due to the opening and/or closing movement of the bucket door, comprising a pendulum arm comprising an upper end with a lateral edge comprising at least one opening to be fixedly connected to the free end of the brake arm, an inner side pivotally connected to a pendulum support, arranged in front of the brake support, allowing rotational movement of the pendulum, and an outer side comprising a plurality of openings defining a predefined inclination; and a lower end comprising a known mass; a locking device on one side of the upper end of the pendulum arm, which allows an inclination position of the pendulum arm to be fixed; a support structure, on which the rest of the elements of said test bench are installed or arranged; and a plurality of sensors that allow measurements of at least the pressure in the brake chambers, the temperature of the fluid in the brake chambers, and the angular velocity and acceleration of the pendulum and brake arm.