Hydraulic System Operator Skill Compensation
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Solution Overview
Problem
Operators of heavy machinery, such as wheel loaders and track-type tractors, often require extensive training due to the gap between simulated and real-world operating experiences, and existing systems rely on operator input to adjust for skill levels, which can be inconsistent.
Innovation Solution
A hydraulic system with a controller that determines the operator's skill level based on machine operating characteristics and adjusts the hydraulic fluid flow rate accordingly, ensuring safer and more controlled machine operation by limiting fluid flow for less skilled operators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hydraulic fluid flow rate is increased to improve productivity, then machine operation speed increases, but the risk of accidents increases for novice operators
Solution Approach 1:
The system dynamically adjusts the hydraulic fluid flow rate based on the operator's skill level. For novice operators, the controller limits the maximum flow rate to safer levels, while allowing experienced operators to access full system capability. This dynamic adjustment resolves the contradiction by making the system adaptive to operator competence rather than fixed.
Solution Approach 2:
The controller changes the operational parameters (hydraulic flow rate limits) based on operator skill level. By modifying the flow rate parameter according to operator experience, the system enables novice operators to work at reduced speeds for safety while maintaining productivity for experienced operators.
2Adaptability or versatility
If manual skill level input is required to adjust hydraulic flow, then customization for operator skill is achieved, but system complexity and operator burden increase
Solution Approach 1:
The system automatically determines operator skill level without manual input by monitoring and analyzing operating characteristics such as control movements, cycle times, and operational patterns. The controller self-adjusts hydraulic flow rates based on this analysis, eliminating the need for operators to manually select skill levels or fill out forms.
Solution Approach 2:
The system continuously monitors operator performance through sensors and provides feedback to the controller, which automatically adjusts hydraulic parameters. This closed-loop feedback mechanism enables the system to adapt to operator skill level dynamically without requiring manual intervention or complex user interfaces.
3Reliability
If extensive training is provided to improve operator skill, then operational competence increases, but training time and cost increase
Solution Approach 1:
The system prepares novice operators for complex machine operation by automatically providing supportive control characteristics from the beginning. The controller limits hydraulic flow rates and provides more stable, predictable machine responses during the learning phase, allowing operators to gain competence more quickly without requiring extensive formal training programs.
Solution Approach 2:
The system cushions novice operators from the full power and responsiveness of the hydraulic system during the learning phase. By pre-limiting flow rates and providing more gradual response characteristics, the system reduces the learning curve and allows operators to build competence with reduced risk before accessing full system capability.
Data Source
AI summary
A hydraulic system for a machine is provided including a first cylinder, a pump and an operator input device for entering a commanded rate of flow of hydraulic fluid to the first cylinder. A control valve operatively is connected between the pump and the first cylinder. A sensor is configured and arranged to provide signals relating to a first operating characteristic of the machine. A controller is in communication with the operator input device, the control valve and the sensor. The controller is configured to determine a skill level of an operator of the machine based on a comparison of the first operating characteristic of the machine and a first threshold and to direct the control valve to provide hydraulic fluid to the first cylinder at an adjusted hydraulic fluid flow rate if the skill level of the operator is below a predetermined level.