Hydraulic Valve Auto-Tuning for Smooth Demolition Robot Control
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Solution Overview
Problem
Contemporary remote demolition robots experience irregular operation due to varying mechanical forces required to open valves, caused by hysteresis and mechanical friction, leading to jerky movements and inconsistent results depending on control switch direction.
Innovation Solution
A controller system that adjusts the control signal for proportional hydraulic valves based on pressure sensor readings to determine and apply starting and stopping offsets, accommodating real-life valve irregularities and ensuring smooth operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a given control signal is used to operate the valve, then the valve opening is determined, but the mechanical force required varies due to hysteresis and friction causing inconsistent operation
Solution Approach 1:
The system uses pressure sensors to detect actual valve opening status and feeds this information back to the controller. The controller compares the actual pressure with expected pressure values and automatically adjusts the control signal to compensate for hysteresis and friction effects, ensuring consistent valve operation regardless of mechanical variations
Solution Approach 2:
The system dynamically changes the control signal parameters (voltage or current levels) based on detected pressure feedback. By adjusting the electrical parameters sent to the proportional valve, the system compensates for mechanical friction and hysteresis, maintaining reliable and consistent valve operation
2Force
If the operator pushes the control switch further to compensate for insufficient valve opening, then the desired mechanical force is achieved, but the operation becomes jerky and irregular
Solution Approach 1:
The pressure sensor provides continuous feedback on the actual valve opening status, allowing the controller to make precise, incremental adjustments to the control signal. This eliminates the need for the operator to push the control switch further, as the system automatically compensates to achieve the desired mechanical force with smooth, controlled movements
Solution Approach 2:
The system performs self-adjustment through the automated feedback loop. The controller monitors pressure readings and independently modifies the control signal to maintain smooth operation, removing the need for manual compensation by the operator and eliminating jerky movements
3Reliability
If the control signal is increased to overcome dead band, then the valve responds more reliably, but the dead band remains perceived as annoying by the operator
Solution Approach 1:
The pressure feedback mechanism detects when the valve is actually opening and allows the controller to compensate for dead band effects automatically. This maintains reliable valve response while preventing the operator from perceiving dead band issues, as the system self-corrects the control signal based on actual valve status
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 solution enables consistent and smooth operation of remote demolition robots by compensating for mechanical friction and hysteresis, providing the same results regardless of control switch direction, thereby reducing operator annoyance and improving robot performance.
Implementation Method 1
receive a pressure sensor reading from a pressure sensor for a proportional hydraulic valve, said pressure sensor reading indicating a standby pressure
Implementation Method 2
provide the control signal to the valve; increase a signal level of the control signal provided to the valve
Implementation Method 3
proportional hydraulic valve
Data Source
Figure 1
Figure 2~7
Figure 4A~4B
AI summary
A remote controlled demolition robot (10) comprising a controller (17) and at least one control switch (24, 25, 26) for providing a control signal that is received by the controller (17), wherein the controller (17) is configured to control the operation of a corresponding robot part (10a, 11, 14, 15). The controller (17) is further configured to: receive a pressure sensor reading from a pressure sensor (13b) for a proportional hydraulic valve (13a), said pressure sensor reading indicating a standby pressure; provide the control signal to the valve (13a); and increase a signal level of the control signal provided to the valve (13a) until a change in the pressure is detected; determine a starting offset for the valve (13a), said starting offset corresponding to the current signal level of the control signal.