Hydraulic Cylinder Stop Control Using a Fluid Buffer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Hydraulic cylinders in boom systems face wear and tear issues due to shocks and vibrations during operation, which existing soft stop functionalities fail to adequately address, potentially leading to damage and increased maintenance.
Innovation Solution
A controller system with a piston position sensor is used to determine the piston's movement direction and stop it at a predetermined distance from the end wall, creating a hydraulic fluid buffer to absorb shocks and reduce wear, with adjustable stop distances based on accessory type and operational conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If soft stop functionality is used to reduce forces at end position, then the forces on end wall and piston are reduced, but the cylinder is still not protected from shocks and vibrations during operation
Solution Approach 1:
The controller aborts the movement command before the piston reaches the end wall, preventing the piston from making contact with the end wall. This preliminary action stops the piston at a predetermined safe distance, thereby eliminating the impact forces and protecting the cylinder from shocks and vibrations during operation, not just at the end position.
2Duration of action of stationary object
If the piston is stopped at a distance from the end wall, then wear and tear of the cylinder is reduced, but the reach of the carrier is limited
Solution Approach 1:
The system dynamically adjusts the stop distance based on operational conditions. The controller can modify the predetermined distance from the end wall where the piston stops, allowing optimization between cylinder protection and operational reach requirements. This dynamic adjustment enables the system to adapt to different accessory types and operational conditions.
Solution Approach 2:
The stop distance parameter is made variable rather than fixed. The controller can change the distance parameter based on the type of accessory being carried and the specific operational conditions, thereby balancing the trade-off between reducing cylinder wear and maintaining adequate operational reach.
3Ease of operation
If operator visibility of end position is improved, then damage prevention is easier, but the operator cannot always know or see when approaching end position
Solution Approach 1:
The system implements automated feedback through the piston position sensor and controller that continuously monitor piston position and compare it to the predetermined stop distance. When the piston approaches the stop distance, the controller automatically aborts the movement command, providing feedback to the operator through the control system without requiring the operator to visually determine end position.
Solution Approach 2:
The manual visual monitoring system is replaced with an automated sensor-based position detection system. The piston position sensor electronically detects the piston position and feeds this information to the controller, which automatically makes the stop decision, replacing the need for operator visual assessment and manual intervention.
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 solution reduces wear and tear on hydraulic cylinders, enhances operational smoothness, and increases the usability of boom systems by effectively mitigating shocks and vibrations, while allowing for adjustable reach and protection based on the type of accessory and operational conditions.
Implementation Method 1
A controller system with a piston position sensor is used to determine the piston's movement direction and stop it at a predetermined distance from the end wall, creating a hydraulic fluid buffer to absorb shocks and reduce wear
Data Source
AI summary
A carrier comprising a hydraulic cylinder having a piston, a controller and a piston position sensor, wherein the carrier is arranged to carry an accessory through the use of the hydraulic cylinder and wherein the controller is configured to: receive piston position information; determine a direction of movement of the piston; and if the piston position equals a stop distance from an end wall of the hydraulic cylinder in the direction of movement, abort the movement.