Excavator Load Torque Measurement via Dynamic Static Separation
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Solution Overview
Problem
Existing load measuring systems for excavating machines, such as power shovels and excavators, face challenges in accurately determining the weight of materials in buckets, particularly due to dynamic and static friction factors, which affect the accuracy of weight calculations and can lead to overloading during truck loading operations.
Innovation Solution
A method involving a load measuring system that includes sensors to measure hoist torque, speed, and acceleration, along with processors to calculate load torque by separating dynamic and static torque components, allowing for precise estimation of material weight in the bucket, and communication systems to ensure that the weight does not exceed the haulage machine's capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If load measuring systems use simple torque sensing without separating dynamic and static components, then device complexity is reduced, but measurement precision deteriorates due to friction factors affecting weight calculation accuracy
Solution Approach 1:
The patent segments the torque measurement into distinct dynamic and static components. The system separates torque due to motion (dynamic) from torque due to friction and gravity (static) through dedicated sensing and calculation pathways, enabling accurate weight determination by isolating the load-specific torque component from frictional interference
Solution Approach 2:
The patent introduces intermediary computational elements that process raw torque signals to extract pure load information. By using intermediate calculation steps that account for friction coefficients and dynamic factors, the system mediates between the complex torque sensor output and the final weight measurement, eliminating friction-related measurement errors
2Measurement precision
If load measuring systems account for dynamic effects and friction compensation, then measurement precision improves, but device complexity increases due to additional sensors and processing requirements
Solution Approach 1:
The patent makes the torque sensor and processing system multi-functional by designing it to simultaneously measure both dynamic load effects and static friction components. The same sensor apparatus serves dual purposes: capturing motion-related torque and friction-related torque, eliminating the need for separate dedicated sensors for each function
Solution Approach 2:
The patent changes the parameter representation by expressing torque in multiple component forms (dynamic component, static component, friction component) rather than as a single aggregate value. This parameter transformation allows the system to extract accurate weight information while accounting for friction, using computational parameter separation rather than additional physical sensors
3Measurement precision
If friction compensation is implemented in load measuring systems, then measurement precision improves, but loss of information decreases as friction factors are properly accounted for in calculations
Solution Approach 1:
The patent converts the harmful effect of friction into a beneficial measurement component. By explicitly measuring and accounting for friction torque as a separate quantifiable parameter, the system transforms friction from a source of measurement error into a known variable that can be compensated for mathematically, improving weight measurement accuracy
Solution Approach 2:
The patent implements feedback mechanisms where measured friction and dynamic parameters are continuously fed back into the weight calculation process. This feedback loop allows the system to adjust weight determinations in real-time based on actual friction conditions and dynamic effects, maintaining measurement precision across varying operational conditions
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 approach enhances the accuracy of material weight determination, preventing overloading and optimizing the loading process by providing real-time feedback to operators, ensuring efficient and safe operation of excavating machines.
Implementation Method 1
a hoist motor adapted to vertically move the bucket
Data Source
AI summary
Certain exemplary embodiments comprise a method for determining a weight of a load associated with an excavating machine, the method comprising: determining a load torque of an excavating machine, the excavating machine comprising a bucket and a hoist motor adapted to vertically move the bucket; and calculating a load weight from the load torque.