Excavator Swing Torque Control via Inertial Measurement
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Solution Overview
Problem
Swing-type excavation machines, such as hydraulic excavators, face inefficiencies due to inaccurate determination of torque consumed by the swing system, leading to inefficient operation and potential power source stalling, as existing control systems struggle to accurately measure torque demand.
Innovation Solution
Incorporating an inertial measurement unit to generate data on the rotation of the upper carriage relative to the work surface and undercarriage, allowing a controller to determine torque consumption by the swing system and adjust total torque demand when it exceeds the power source's maximum capacity by reducing torque received from other systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the control system predicts/estimates torque consumed by the swing system, then the control system can operate without additional sensors, but the torque determination becomes inaccurate leading to inefficient machine operation
Solution Approach 1:
The patent replaces mechanical torque sensing devices with an inertial measurement unit (IMU) that uses accelerometers and gyroscopes to measure rotational motion. The IMU captures linear acceleration, rotational velocity, and rotational acceleration data, which are then processed to calculate swing system torque. This substitution eliminates the need for complex mechanical torque sensors while achieving accurate torque determination through dynamic motion measurement and computational analysis.
2Reliability
If the control system uses traditional torque determination methods, then the system structure remains simple, but the total torque demand cannot be accurately determined causing power source stalling
Solution Approach 1:
The patent implements a feedback mechanism where the IMU continuously monitors the swing system's rotational motion and provides real-time data to the controller. The controller processes this data to calculate actual torque consumption, compares it with predicted torque, and adjusts control signals to hydraulic actuators accordingly. This closed-loop feedback system ensures accurate total torque demand determination and prevents power source stalling by maintaining reliable torque measurement throughout operation.
3Productivity
If the control system accurately determines torque consumed by each system, then efficient machine operation is achieved, but the complexity of torque measurement and control increases
Solution Approach 1:
The patent makes the inertial measurement unit serve multiple functions: it measures swing system torque, determines machine rotation dynamics, provides data for control algorithms, and enables productivity optimization. By using a single IMU device for multiple measurement and control purposes, the system achieves accurate torque determination for efficient operation without proportionally increasing device complexity. The controller also performs multiple functions including torque calculation, control signal generation, and system coordination.
Data Source
AI summary
A method for controlling a machine. The machine includes a swing system and a plurality of systems. The method comprises generating, by an inertial measurement unit, data pertaining to rotation of an upper carriage of the machine relative to a work surface, determining, by a controller, data pertaining to rotation of the upper carriage relative to an undercarriage of the machine based on the data generated by the inertial measurement unit. The method includes determining, by the controller, an amount of torque received by the swing system from a power source based on the data pertaining to the rotation of the upper carriage relative to the undercarriage, determining, by the controller, a total torque demand based on the first amount of torque and adjusting, by the controller, the total torque demand when the total torque demand exceeds a maximum torque capacity of the power source.