Hydraulic Tool Pressure Monitoring for Jam and Fault Detection
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Solution Overview
Problem
Hydraulic tools on earth movers face reliability issues due to harsh environmental conditions and operational problems, leading to downtime and reduced productivity, as existing sensor systems are vulnerable to temperature, vibrations, and other environmental factors, and lack effective monitoring for jamming and faults.
Innovation Solution
A prime mover mountable hydraulic tool with a protective box assembly housing hydraulic pressure sensors, a control circuit, and a wireless transmitter antenna, along with a system for detecting jamming and faults using data acquisition, processing, and statistical analysis in a cloud-based system, which includes a data acquisition module, jam detection module, and fault detection module to identify anomalies and predict issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are exposed to harsh environments for monitoring hydraulic tools, then monitoring capability is improved, but sensor longevity and reliability deteriorate due to temperature, vibrations, dirt, and rain
Solution Approach 1:
The patent introduces a protective enclosure as an intermediary between the sensors and the harsh environment. This enclosure shields the sensors from direct exposure to temperature extremes, vibrations, dirt, and rain, while still allowing the sensors to perform their monitoring function. The enclosure acts as a mediator that preserves sensor reliability without compromising monitoring capability.
Solution Approach 2:
The system is divided into separate functional components: the protective enclosure housing the sensors, the hydraulic tool itself, and the communication interface. This segmentation allows the sensors to be protected in the enclosure while still monitoring the hydraulic tool's operation, resolving the contradiction between exposure for monitoring and protection for reliability.
2Device complexity
If hydraulic tools operate without effective monitoring systems, then device complexity is reduced, but productivity deteriorates due to unplanned downtime from jamming and faults
Solution Approach 1:
The patent implements a feedback mechanism where sensors continuously monitor hydraulic tool operation and transmit data through a wireless interface to a monitoring system. This feedback loop enables real-time detection of jamming and faults, allowing for timely intervention before complete failure occurs, thus maintaining productivity without requiring complex manual monitoring systems.
Solution Approach 2:
The monitoring system enables the hydraulic tool to effectively monitor itself for faults and jamming conditions. The sensors and wireless interface allow the system to self-diagnose issues without external intervention, reducing the need for complex external monitoring infrastructure while maintaining high productivity through continuous self-monitoring.
3Device complexity
If communication channels depend on the prime mover's system, then device complexity is reduced, but reliability deteriorates due to potential communication failures affecting user interface
Solution Approach 1:
The wireless interface is designed to provide communication capability that is independent of the prime mover's communication system. This universal communication interface can operate autonomously, ensuring that the user interface remains functional even when the prime mover's communication system fails, thus improving reliability without significantly increasing complexity.
Data Source
AI summary
A hydraulic tool with a protective box assembly including a control circuit and hydraulic pressure sensors is used to operate a prime mover. The control circuit and the hydraulic pressure sensors are used to monitor performance of the hydraulic tool. Systems and methods implemented in a cloud monitor the performance of the hydraulic tool. The systems and methods utilize data collected by the hydraulic pressure sensors, processed by the control circuit, and transmitted via an antenna from the hydraulic tool to the cloud. A first set of systems and methods detect and predict a jam condition in blades associated with the hydraulic tool using statistical analysis of the data. A second set of systems and methods detect faults associated with the hydraulic tool including hydraulic leakage, mechanical wear, and friction.