Hydraulic Cylinder Pressure Sensing for Coupling State Detection
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Solution Overview
Problem
Existing safety systems for hydraulic couplings in machinery fail to accurately detect various states of the coupling mechanism, leading to potential unsafe connections and risks of injury or equipment damage, and often require additional components that increase hydraulic system energy consumption.
Innovation Solution
A safety system using pressure sensors to measure pressure within the pressure chamber of a hydraulic cylinder via spaced channels, combined with a seal device that moves over the channels, allows detection of multiple states, including piston locked, activated but blocked, fully extended, and fully retracted positions, without additional system restrictions or energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a restriction is added to the hydraulic supply line to measure displaced hydraulic fluid, then the stroke length of the piston can be determined, but the hydraulic pressure increases and the system requires more energy
Solution Approach 1:
A seal device is introduced as an intermediary element that moves over openings in the hydraulic supply line. The seal device blocks the openings at different positions to indicate piston stroke length, eliminating the need for flow restrictions while maintaining measurement capability
Solution Approach 2:
The patent replaces the flow-restriction-based measurement system with a mechanical blocking system using a seal device that physically covers openings. This substitution eliminates energy loss through restrictions while preserving position detection functionality
2Reliability
If inductive sensors and metal rings are used to detect coupling position, then the closed position can be detected, but the fully extended and fully retracted positions cannot be detected
Solution Approach 1:
The detection system is segmented into multiple independent openings along the hydraulic supply line, each corresponding to a specific piston position. This allows independent detection of fully retracted, partially extended, and fully extended states without interference
Solution Approach 2:
The patent transitions from point-based detection (single sensor location) to distributed detection along the length of the hydraulic supply line. Multiple openings are positioned at different locations to detect different piston positions, adding spatial dimension to the detection capability
3Measurement precision
If multiple sensors and special rod configurations are added to detect coupling states, then detection accuracy improves, but device complexity increases
Solution Approach 1:
The hydraulic supply line serves multiple functions: it provides hydraulic fluid to the cylinder and simultaneously acts as a position indicator through strategically placed openings. The seal device blocks these openings to indicate piston position, combining fluid delivery and measurement functions in a single system
Solution Approach 2:
The patent merges the hydraulic fluid delivery system with the position detection system. The same hydraulic supply line that delivers fluid also contains the openings used for detection, eliminating the need for separate sensor assemblies and reducing overall system complexity
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 provides robust, versatile, and reliable detection of hydraulic cylinder states, ensuring safe tool connections by identifying unsafe conditions and enhancing overall safety and efficiency.
Implementation Method 1
a first pressure sensor and a second pressure sensor, the first and second pressure sensors being designed to measure the pressure within the pressure chamber via a first channel and a second channel
Data Source
AI summary
A safety system for a machine includes a pressurizing device; at least one hydraulic cylinder, the at least one hydraulic cylinder including a pressure chamber and a piston having a head and a rod, the piston being movable within the pressure chamber along a longitudinal direction; a first pressure sensor and a second pressure sensor being designed to measure the pressure within the pressure chamber via a first channel having a first opening and a second channel having a second opening, which both extend into the pressure chamber, and are spaced apart as seen in the longitudinal direction; a seal device arranged circumferentially around the head of the piston, and a hydraulic system being fluidically connected to a head side and a rod side of the at least one hydraulic cylinder, the hydraulic system being fluidically connected to a hydraulic fluid reservoir and the pressurizing device.