Hydraulic Boom Tool Alignment Using Pressure and Piston Feedback
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Solution Overview
Problem
Operators face challenges in aligning construction or demolition tools, such as hydraulic hammers or drills, at the correct angle due to safety and convenience limitations, leading to potential damage and increased wear from improper force application.
Innovation Solution
A system comprising a carrier with hydraulic cylinders, a controller, piston position sensors, and pressure sensors that guide the tool to the correct angle by determining contact with the subject and adjusting the tool's position based on hydraulic pressure and piston position information, allowing the operator to maintain control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the operator manually aligns the tool without automated assistance, then the operator maintains full control of the boom, but it is difficult for the operator to set the tool at the correct angle due to safety and convenience limitations
Solution Approach 1:
The system continuously monitors hydraulic pressure and piston position, providing real-time feedback to the operator about tool alignment status. The controller processes sensor data to determine contact between the tool and subject, enabling the operator to achieve correct alignment with feedback guidance while maintaining control.
Solution Approach 2:
The patent replaces manual visual estimation and physical adjustment with automated sensing systems. Pressure sensors and piston position sensors substitute for the operator's manual alignment efforts, providing objective measurement data that guides the operator to the correct angle without removing operator control.
2Measurement precision
If automated angle setting is implemented, then the tool can be aligned at the correct angle automatically, but the control of the boom is taken away from the operator which may cause unexpected movement and endanger operators or bystanders
Solution Approach 1:
The system performs self-monitoring of alignment status through pressure and position sensors, automatically determining when the tool is correctly aligned. However, the final alignment action and boom control remain with the operator, combining automated assessment with manual execution to maintain safety.
Solution Approach 2:
The automated system provides feedback about alignment status without taking control away from the operator. The controller monitors parameters and communicates alignment information to the operator, who then makes the final positioning decisions, ensuring both precision and operator control.
3Productivity
If the tool engages the subject at an incorrect angle, then the operator can proceed with operation, but the resulting forces cause damage to or increased wear of the tool
Solution Approach 1:
The system performs preliminary assessment of tool alignment before the operator proceeds with forceful engagement. By checking pressure and position data in advance, the system alerts the operator to incorrect angles before significant wear or damage occurs, preventing reliability issues while allowing continued operation.
Solution Approach 2:
Real-time monitoring of hydraulic pressure provides continuous feedback about the forces applied during operation. When abnormal pressure patterns indicate incorrect engagement angles, the system alerts the operator to adjust the tool position, preventing damage while allowing efficient operation when properly aligned.
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
Ensures proper alignment of tools, reducing wear and tear, maintaining operator control, and preventing damage by providing real-time guidance for achieving the desired angle.
Implementation Method 1
a pressure sensor for detecting hydraulic pressure in at least one hydraulic cylinder
Implementation Method 2
a piston position sensor for detecting a position of a piston in the at least one hydraulic cylinder
Data Source
Figure 1
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AI summary
A carrier (10) comprising at least one hydraulic cylinder (12) having a piston (12b), a controller (17), a piston position sensor (12j) and a pressure sensor (13c) for detecting hydraulic pressure in at least one hydraulic cylinder (12), wherein the carrier (10) is arranged to carry a tool (11b) through the use of the hydraulic cylinder (12) and wherein the controller (17) is configured to: receive control input for moving the tool (11b) towards a subject (S); receive tool operation information comprising at least piston position information for at least one piston of the at least one hydraulic cylinder (12) and; receive hydraulic pressure information for the at least one hydraulic cylinder (12); determine whether the tool (11b) is in contact with the subject (S) based on the hydraulic pressure information, and if so; determine a position of the subject (S) relative the carrier (10) based on tool operation information.