Hydraulic Coupler Fault Detection via Pressure Asymmetry Analysis
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Solution Overview
Problem
Existing work machines with lift components face challenges in detecting abnormal lifting cycles due to operator error or faulty couplers, leading to delayed identification of issues that can reduce productivity and cause equipment breakdowns.
Innovation Solution
A method involving pressure sensors and an electronic control module with a fault detection algorithm that senses pressure asymmetry in hydraulic cylinders during lifting cycles to indicate abnormal conditions, distinguishing between operator error and coupler faults by prompting a second lift for verification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If regularly scheduled maintenance inspection is used to detect coupler problems, then detection capability is provided, but detection timing is delayed and productivity is reduced
Solution Approach 1:
The system performs continuous monitoring of lifting cycle parameters (speed, position, force) in real-time during operation, rather than waiting for scheduled maintenance. The fault detection algorithm continuously analyzes data to identify abnormal patterns, enabling early detection of coupler problems before they cause breakdowns or safety issues.
Solution Approach 2:
The system provides continuous feedback by monitoring lifting cycle parameters and comparing them against expected ranges. When abnormalities are detected (such as unexpected speed variations, position deviations, or force anomalies), the system immediately alerts operators or automatically adjusts operations, creating a closed-loop monitoring system that enables timely intervention.
2Reliability
If operator inspection during maintenance is used, then detection is performed, but human error affects accuracy and technicians may not be alerted to performance issues
Solution Approach 1:
The system performs self-monitoring and self-diagnosis by automatically analyzing lifting cycle data through the fault detection algorithm. It independently identifies abnormalities without requiring operator intervention or technician inspection, eliminating human error in detection and ensuring consistent, objective monitoring of coupler performance.
Solution Approach 2:
The system continuously provides feedback about coupler health status through automated analysis of lifting parameters. It monitors for patterns indicating wear, misalignment, or component failure and alerts operators immediately, ensuring that performance issues are communicated promptly and accurately without relying on manual inspection or technician memory.
3Loss of time
If continuous monitoring with fault detection algorithm is implemented, then timely and accurate detection is achieved, but device complexity increases
Solution Approach 1:
The system leverages existing multi-functional sensors already present in the work machine (speed sensors, position sensors, force sensors) for both normal operation monitoring and fault detection. The same sensors that control lifting operations also provide data for the fault detection algorithm, eliminating the need for separate dedicated monitoring hardware and reducing overall system complexity.
Solution Approach 2:
The system replaces manual mechanical inspection with automated electronic sensing and computational analysis. Instead of relying on physical inspection during maintenance, the system uses electronic sensors and algorithms to continuously monitor and detect faults, reducing operational complexity while improving detection timing and accuracy.
4Productivity
If undetected coupler faults are allowed to continue, then operation can proceed, but breakdown occurs during operation causing time and money loss
Solution Approach 1:
The system detects and alerts operators to developing faults during normal operation, enabling preliminary maintenance actions before breakdown occurs. By continuously monitoring lifting cycle parameters and identifying abnormal patterns early, the system allows operators to schedule maintenance during convenient times rather than responding to sudden failures, maintaining operational continuity while preventing breakdowns.
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 provides an accurate and timely detection of faulty couplers or operator errors, reducing downtime and maintenance costs by identifying issues before they cause significant damage, and improving operator training through real-time monitoring and feedback.
Implementation Method 1
at least one pressure sensor senses a pressure within a hydraulic cylinder of the coupler
Data Source
AI summary
An abnormal lifting cycle of a work machine lift component can be indicative of operator error and/or a fault within a lift component coupler. The present disclosure includes a method of detecting a fault for a lift component coupler of a work machine. Pressure within at least one hydraulic cylinder of the coupler is sensed during at least a portion of a lifting cycle of the lift component. A condition of the lifting cycle can be determined by detecting a magnitude of asymmetry within a plurality of the sensed pressures. An abnormal condition of the lifting cycle is indicated if the magnitude of the asymmetry of the plurality of the sensed pressures is outside of a predetermined range of asymmetry.