Hydraulic Cylinder Stop Control for Shock and Wear Reduction
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Solution Overview
Problem
Hydraulic cylinders used in boom systems face wear and tear issues due to shocks and vibrations, which existing soft stop functionalities do not adequately address, leading to potential damage and increased maintenance.
Innovation Solution
A system comprising a hydraulic cylinder with a piston position sensor and controller that determines the piston's direction and position, controlling the piston to stop 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 the accessory type and operational conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soft stop functionality is used to reduce forces at end position, then wear and tear on end walls is reduced, but the cylinder is still subjected to shocks and vibrations during operation
Solution Approach 1:
The controller receives piston position information and determines when the piston is approaching the end position before actual contact occurs. By proactively controlling the hydraulic flow in advance, the system prepares to reduce piston speed before the harmful contact happens, thereby preventing shocks and vibrations from reaching the end wall while maintaining cylinder durability
2Object-affected harmful factors
If the piston is stopped early from the end wall, then shocks are reduced, but the usable travel distance of the cylinder is reduced
Solution Approach 1:
The system continuously receives piston position information from the position sensor and feeds this back to the controller. The controller uses this real-time feedback to dynamically adjust the hydraulic flow control, stopping the piston at the optimal position that provides adequate buffer distance for shock absorption while maximizing the usable travel distance. This closed-loop control resolves the contradiction by making the stop position adaptive rather than fixed
3Reliability
If operator awareness of end position is improved, then damage can be prevented, but the operator cannot always see or know when approaching end position
Solution Approach 1:
The system performs self-monitoring through the piston position sensor that automatically tracks the piston position without requiring operator attention. The controller autonomously processes the position information and independently controls the hydraulic flow to prevent end-position damage, freeing the operator from the burden of manually monitoring cylinder positions while ensuring reliable damage prevention
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 carriers by effectively mitigating shocks and vibrations, allowing for adjustable reach and protection based on the accessory and operational parameters.
Implementation Method 1
creating a hydraulic fluid buffer to absorb shocks and reduce wear
Data Source
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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.