Fluid Circuit Sensor Failure Estimation Algorithm
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Solution Overview
Problem
Conventional electro-hydraulic systems lose control or experience severe degradation when pressure or position sensors fail, leading to temporary shutdowns and suboptimal operation, as existing code-based methods are inadequate for continuous fluid circuit operation.
Innovation Solution
A controller with an algorithm that estimates or reconstructs the output value of a failed sensor using a predetermined load configuration and non-linear equations, allowing for continuous operation by processing output values from remaining sensors and controlling the fluid circuit until the sensor can be repaired or replaced.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If code-based methods are used to detect sensor failures, then sensor failure detection capability is improved, but system continuity and operational stability deteriorate due to temporary shutdowns
Solution Approach 1:
The patent introduces an intermediary estimation algorithm that acts as a mediator between sensor failure detection and system control. When a sensor fails, the algorithm estimates the missing sensor value using data from other sensors and system models, allowing the control system to continue operating without shutdown while maintaining awareness of the failure condition
Solution Approach 2:
The system prepares for sensor failures in advance by implementing redundancy through the estimation algorithm. Before a failure causes system shutdown, the cushioning mechanism of value estimation is already in place to compensate for the missing sensor data, preventing the harmful effect of operational interruption
2Device complexity
If conventional sensor monitoring methods are used, then system simplicity is maintained, but control stability deteriorates when sensors fail
Solution Approach 1:
The system performs self-service by using its own existing sensors and control data to estimate the value of a failed sensor. The estimation algorithm leverages the system's inherent information (other sensor readings, system models, operational data) to compensate for the failure, maintaining control stability without requiring external intervention or complex additional hardware
Data Source
AI summary
A fluid circuit includes a tank for holding fluid, a hydraulic device having a predetermined load configuration, and a pump for delivering the fluid under pressure to the hydraulic device. Sensors measure at least one of a supply pressure, a tank pressure, and a position of a portion of the hydraulic device. A controller estimates or reconstructs an output value of any one sensor using the predetermined load configuration in the event of a predetermined failure of that sensor, ensuring continued operation of the hydraulic device. A method for estimating the output value includes sensing output values using the sensors, processing the output values using the controller to determine the presence of a failed sensor, and calculating an estimated output value of the failed sensor using the predetermined load configuration. Operation of the hydraulic device is maintained using the estimated output value until the failed sensor can be repaired.