Hydraulic Coupler Control System with Leak Detection
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Solution Overview
Problem
Existing hydraulic coupler control systems fail to detect hydraulic ram failures or hose damage, leading to potential detachment of attachments from excavators, posing safety hazards and environmental risks due to undetected loss of hydraulic oil.
Innovation Solution
A control system incorporating flow and pressure sensors with audible and visual alerts to notify operators of fluid leaks or pressure loss, allowing for self-testing during normal operation, and including a solenoid-operated valve for controlling fluid flow to the ram.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional hydraulic control systems are used without monitoring devices, then the system structure remains simple, but the reliability of detecting hydraulic failures is poor
Solution Approach 1:
The system performs preliminary detection of hydraulic failures before they cause dangerous situations. Flow sensors and pressure sensors are installed to detect abnormalities in advance, allowing the control unit to activate warning signals before the attachment detaches, thus improving reliability through proactive monitoring.
Solution Approach 2:
A control unit is introduced as an intermediary component that receives signals from flow sensors and pressure sensors, processes the information, and activates warning signals. This intermediary layer enables reliable failure detection while maintaining manageable system complexity through modular architecture.
2Adaptability or versatility
If hydraulic hoses are continuously flexed during operation, then the coupler can accommodate arm movement, but the hoses are prone to damage causing premature wear and failure
Solution Approach 1:
The system performs preliminary detection of hose damage through flow sensors and pressure sensors that monitor hydraulic parameters. When a hose shows signs of damage (leakage, reduced flow), the sensors detect the abnormality and trigger warning signals before complete failure occurs, allowing preventive replacement.
Solution Approach 2:
The control system continuously monitors hydraulic flow and pressure, providing real-time feedback on hose condition. When parameters deviate from normal ranges indicating hose degradation, the system generates warnings, creating a feedback loop that enables proactive maintenance and extends hose service life.
3Reliability
If hydraulic oil is lost due to hose failure, then the hydraulic system loses pressure, but the environmental pollution from oil leakage increases
Solution Approach 1:
The system detects hose damage and oil leakage in advance through flow sensors that monitor for unexpected flow patterns and pressure sensors that detect pressure drops. When leakage is detected, warning signals are activated immediately, allowing operators to address the issue before significant oil loss and environmental pollution occur.
Solution Approach 2:
The monitoring system provides continuous feedback on hydraulic system integrity. Flow sensors detect abnormal flow indicating leakage, and pressure sensors confirm pressure loss, creating a feedback mechanism that alerts operators to potential environmental hazards before they materialize into significant pollution events.
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
The system effectively alerts operators to hydraulic failures, ensuring safe attachment engagement and reducing environmental pollution by detecting pressure and flow issues, enabling self-testing and prolonging hydraulic pipe life through reduced surges.
Implementation Method 1
a flow sensor for sensing the flow of fluid in a feed line for supplying pressurised fluid to the ram
Implementation Method 2
a pressure sensor for sensing the pressure of fluid in said feed line
Implementation Method 3
including a solenoid-operated valve for controlling fluid flow to the ram
Data Source
AI summary
A control system for extending and retracting a ram of a hydraulic coupler for coupling an attachment to an arm of an excavator or back hoe, said control system being adapted to provide an audible and/or visual alert to an operator to indicate a leak of fluid or loss of fluid pressure from said ram and/or from a hydraulic circuit supplying said fluid to the ram. Preferably the control system further comprises a flow sensor for sensing the flow of fluid in a feed line for supplying pressurized fluid to the ram and/or a pressure sensor for sensing the pressure of fluid in said feed line, said control system including at least one indication device for providing said audible and/or visual alert to an operator to indicate a leak of fluid or loss of fluid pressure in response to, or as a function of, the output of the flow sensor and/or the pressure sensor.