Excavator Engine Self-Testing via Hydraulic Load Application
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Solution Overview
Problem
Construction machines, such as excavators, face challenges in identifying the source of power limitations due to issues like faulty engine components and sensor calibration problems, making it difficult to diagnose and load the engine effectively, especially in remote areas where transportation for testing is impractical.
Innovation Solution
An excavator system that includes test generation logic to apply controlled loads on the engine, using hydraulic actuators and sensors to detect engine response, allowing for self-testing and data logging of performance characteristics, enabling remote diagnosis and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the excavator is transported to a testing facility for diagnosis, then accurate engine performance testing can be performed, but transportation costs increase and operational downtime extends
Solution Approach 1:
The excavator performs self-diagnosis by using its own hydraulic system to apply controlled loads to the engine and measure the response. The control system automatically executes test sequences, collects sensor data, and identifies engine performance issues without requiring external testing facilities or transportation.
Solution Approach 2:
The system performs preliminary engine performance testing directly at the worksite before problems worsen or require expensive transportation. By conducting tests in advance using available onboard resources, the system prevents the need for later facility-based diagnostics.
2Reliability
If traditional manual testing methods are used, then engine performance can be evaluated, but the process requires specialized facilities and extended downtime
Solution Approach 1:
The hydraulic system serves multiple functions: it performs normal excavator operations and simultaneously functions as a test load application system for engine diagnostics. The control system also manages both operational control and test sequence execution, eliminating the need for separate specialized testing equipment.
Solution Approach 2:
The control system acts as an intermediary that coordinates between the hydraulic system (which applies load), the engine (which responds), and the sensor system (which measures response). This integrated control approach enables reliable testing without complex external testing infrastructure.
3Ease of operation
If the hydraulic system is used for normal operations only, then operational simplicity is maintained, but engine self-testing capability is lost
Solution Approach 1:
The hydraulic system dynamically switches between operational mode and test mode based on control system commands. During normal operation, it performs excavation tasks; during designated test sequences, it automatically applies controlled loads to the engine. This dynamic versatility is managed transparently to maintain operational simplicity.
Solution Approach 2:
The diagnostic testing functionality is merged with the existing hydraulic system and control architecture. Rather than adding separate testing equipment that would complicate operation, the system combines engine testing capabilities with the already-present hydraulic power system and electronic control infrastructure.
Data Source
AI summary
An engine on an excavator provides power to a hydraulic pump that pumps hydraulic fluid under pressure to a hydraulic actuator. The hydraulic actuator is controlled to place a load on the engine. Engine response to the load placed on it by the hydraulic actuator is detected and logged. The logged engine response data can be accessed to identify engine response.