Hydraulic Sensor Recalibration via Pressure Averaging
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Solution Overview
Problem
Hydraulic actuation systems face operational issues due to pressure sensors losing calibration or falling out of detection range, leading to loss of critical data and system inoperability.
Innovation Solution
A method for resetting the calibration of out-of-range sensors in hydraulic actuation systems involves detecting the sensor's deviation, relieving pressure, resetting all sensors to reservoir pressure, and assigning an average pressure value to recalibrate the sensor within the permitted error band, or generating a malfunction signal if outside the error band.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the sensor operates out of the prescribed range, then the system can continue running, but the measurement precision deteriorates and critical data is lost
Solution Approach 1:
The system performs preliminary calibration actions by establishing reference pressure values (P1 at reservoir pressure, P2 at maximum pump pressure) before normal operation. When a sensor drifts out of range, the system can recalibrate it by comparing against these pre-established reference values, allowing continuous operation while restoring measurement precision.
Solution Approach 2:
The system changes the operating parameters of the sensor by exposing it to different pressure conditions (reservoir pressure and maximum pump pressure) to recalibrate its output. By adjusting the sensor's exposure to these extreme pressure parameters and comparing readings across multiple sensors, the system restores the out-of-range sensor to proper measurement accuracy.
2Productivity
If the sensor is recalibrated while the system is running, then productivity is maintained, but the complexity of the calibration process increases
Solution Approach 1:
The same pressure sensing system serves multiple functions: it monitors normal operating pressures and simultaneously performs self-calibration by comparing readings against reference values established at extreme pressure points. This multi-functionality allows recalibration without requiring separate calibration equipment or system shutdown.
Solution Approach 2:
The system performs self-calibration using its own sensors and pressure extremes (reservoir and pump maximum) as reference points. The controller automatically identifies out-of-range sensors and recalibrates them by comparing readings against the established reference values, eliminating the need for external calibration equipment or manual intervention.
3Reliability
If the sensor reading is used outside the permitted error band, then the system may generate false data, but shutting down the system to recalibrate causes loss of productivity
Solution Approach 1:
The system continuously monitors sensor readings against the permitted error band and automatically triggers recalibration when a sensor drifts outside acceptable ranges. The controller provides feedback by comparing current sensor readings with reference values and adjusts the sensor calibration in real-time, maintaining data reliability without system shutdown.
Solution Approach 2:
The recalibration process is designed to occur continuously during normal system operation. By using the existing pressure extremes (reservoir and pump maximum) as calibration references, the system maintains uninterrupted operation while restoring sensor accuracy, ensuring both reliability and continuous productivity.
Data Source
AI summary
A method for resetting a calibration of a sensor operating out-of-range in a hydraulic actuation system is provided. The hydraulic actuation system includes a pump, a reservoir, a plurality of work-ports, a plurality of sensors, and a valve system, and a controller for regulating the hydraulic actuation system based on fluid flow demand and sensed pressures. The method includes detecting the sensor operating out-of-range, opening all work-ports to the reservoir, resetting all sensors to reservoir pressure, supplying all sensors with fluid at maximum pump pressure, and sensing the maximum pump pressure at each sensor. Additionally, the method includes determining an average pressure value across all sensors, assigning the determined average pressure value to the sensor that is operating out-of-range, and resetting the calibration of the sensor that is operating out-of-range based on the reservoir pressure and the average pressure values.