Excavator Engine Coupled Start-Stop Control With Emergency Relay Backup
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Solution Overview
Problem
Existing excavator control systems lack asynchronous control of power-off and flame-out, and fail to ensure safe emergency start-stop operations, posing reliability and safety risks.
Innovation Solution
A control device and method that integrates a main controller, switch control unit, and engine controller with redundant design, utilizing bus connections and emergency mode relays to enable asynchronous control and emergency start-stop, ensuring uninterrupted power supply during flame-out and allowing direct control when the main controller fails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If direct drive control with key switch is used, then electrical principle is simpler and reliability is better, but degree of intelligence is low and asynchronous control of power-off and flame-out is unavailable
Solution Approach 1:
The control system is segmented into multiple independent controllers (main controller, engine controller, switch control unit) that can operate autonomously. This allows the system to provide both simple direct-drive control and complex intelligent control with asynchronous power-off and flame-out capabilities, resolving the contradiction between simplicity/reliability and intelligence/versatility.
Solution Approach 2:
The control system dynamically switches between different control modes (direct drive mode and intelligent control mode) based on operational requirements. The emergency mode relay and switch control unit enable the system to adapt its control strategy in real-time, providing both simple and intelligent control functions as needed.
2Adaptability or versatility
If controller coupling control system is used, then intelligent start control is achieved, but flame-out cannot be asynchronously actuated and control redundancy is lacking
Solution Approach 1:
The system incorporates emergency mode relays and redundant control paths in advance to prepare for controller failures. When the main controller fails, the emergency mode relay activates alternative control circuits that allow the engine controller and switch control unit to continue operating independently, providing fail-safe functionality and control redundancy.
Solution Approach 2:
The switch control unit acts as an intermediary between the main controller and engine controller, providing alternative control paths. When the main controller fails, the switch control unit can directly control the engine controller through the emergency mode relay, ensuring continuous safe operation and asynchronous flame-out capability.
3Device complexity
If single control mode is used, then device complexity is reduced, but emergency start-stop and danger avoidance operations cannot be implemented
Solution Approach 1:
The control system is designed with multi-functionality to handle both normal operations and emergency situations. The emergency mode relay and switch control unit enable the system to perform multiple functions: normal coupled control, emergency independent control, asynchronous power-off, and forced flame-out operations, all within a unified control architecture.
Solution Approach 2:
The system changes its operational parameters and control strategies based on the situation. In normal operation, it uses coupled control mode; in emergency situations, it switches to independent control mode with modified signal paths through the emergency mode relay, enabling diverse operations without requiring completely separate systems.
Data Source
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AI summary
The present invention discloses a control device and method for engine coupling of an excavator. The control device includes a main controller, a switch control unit and an engine controller that are electrically connected with one another; the main controller is connected to the switch control unit and the engine controller by means of a bus, respectively; and an electronic monitor, an emergency stop switch and an emergency mode relay are connected onto the man controller. The separate control for power supply control and engine start-stop is achieved by the independent design of a power-on switch and a start-stop switch, intelligent start-stop control is further achieved by start-stop of controller coupling, and meanwhile, the purpose of uninterrupted control power supplied to a system key switch during flame-out is achieved by coupling shutdown via the controllers; and when the controllers fail, a contact state of a safety relay can be converted to switch a power supply and start a loop, and a start-stop loop can be switched from coupling control to direct control by means of the emergency mode relay, thereby improving the reliability of a start-stop control system.