Hybrid Torque Control for Industrial Machines With Limited Inputs
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Solution Overview
Problem
Industrial machines often lack an accelerator pedal and have limited ECU components, making it challenging to calculate required torques and determine operation modes for hybrid systems, as compared to hybrid vehicles.
Innovation Solution
A hybrid system for industrial machines that includes a rotation sensor, an accelerator opening-degree sensor or a rotation-number instruction unit, and a control unit. The control unit calculates a torque determining factor based on accelerator opening degree or rotation-number signals, and uses this factor to determine system and engine required torques, allowing for proper operation mode determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the hybrid system is mounted on industrial machines without accelerator pedals or with limited ECU components, then the device complexity is reduced, but the ability to calculate required torque and determine operation modes deteriorates due to limited input factors
Solution Approach 1:
The patent introduces a torque determining factor as an intermediary parameter that bridges the gap between limited direct measurements and the required torque calculation. Instead of directly measuring all necessary torque components, the system uses the torque determining factor (derived from available sensors like rotation sensors or accelerator position sensors) as a mediator to infer the system required torque and engine required torque through pre-stored map data relationships.
Solution Approach 2:
The system uses its own available resources (rotation sensor, accelerator position sensor, and pre-stored map data) to self-determine the required torque without external assistance from additional expensive sensors or complex ECU components. The control unit processes the limited input factors it already has to generate the necessary torque information for hybrid system control.
2Ease of manufacture
If fewer sensors and ECU components are used in industrial machines, then the manufacturing cost and device complexity are reduced, but the precision of torque calculation and operation mode determination deteriorates
Solution Approach 1:
The patent performs preliminary action by pre-storing map data that contains the relationships between torque determining factors, system required torque, and engine required torque before the actual operation. This allows the control unit to quickly and accurately determine torque values during runtime by simply referencing the pre-calculated map data, eliminating the need for complex real-time calculations or additional sensors.
Solution Approach 2:
The system changes the approach from directly measuring multiple torque parameters to using a single torque determining factor parameter that can be easily obtained from available sensors. By transforming the problem into parameter space where one parameter (torque determining factor) can represent the state needed to derive multiple torque values through map data lookup, the system achieves both simplicity and precision.
Data Source
AI summary
A hybrid system which can calculate various type of more proper required torques is provided while input factors which can be used for calculating the various types of required torques are limited.A hybrid system 2 includes a rotation sensor 31 which detects a rotation number of an engine 3, at least either one of an accelerator opening-degree sensor 61 which detects an accelerator opening degree and a rotation-number instruction unit 62 which transmits a rotation-number signal instructing a certain rotation number to the engine 3, and a control unit 5 which controls an operation of the engine 3. The control unit 5 executes control of calculating a torque determining factor for determining a system required torque as the hybrid system 2 on the basis of at least either one of the accelerator opening degree detected by the accelerator opening-degree sensor 61 and the rotation-number signal transmitted by the rotation-number instruction unit 62 and control of calculating the system required torque on the basis of the rotation number detected by the rotation sensor 31 and the calculated torque determining factor.