Hydrovac Safe-State Shutdown with Sequential Boom Isolation
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Solution Overview
Problem
Hydrovac operations pose risks in emergency situations due to the need for rapid shutdown while preserving machinery longevity, as abrupt shutdowns can cause damage and reduce system lifespan.
Innovation Solution
A hydrovac system with a controller that manages a sequential shutdown process upon loss of remote control communication, including opening an emergency shutoff valve, closing a boom isolation assembly, disengaging power take-offs, and reducing engine speed to idle, maintaining hydraulic pressure to secure the boom position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If abrupt shutdown is performed in emergency situations, then rapid stopping of hydrovac operations is achieved, but machinery damage occurs and system longevity is reduced
Solution Approach 1:
The system dynamically adjusts the shutdown process based on emergency severity. The controller sequentially activates multiple shutdown stages (first closing isolation valves, then closing main shut-off valves, and finally shutting down the engine) rather than using a fixed abrupt shutdown method, allowing the system to adapt between rapid response and machinery protection
Solution Approach 2:
The shutdown process is divided into distinct segments or stages: (1) closing isolation valves on hydraulic lines, (2) closing main fuel and air shut-off valves, and (3) shutting down the engine. This segmentation allows each component to be stopped in a controlled manner, preventing sudden stress on the entire system while still achieving rapid overall shutdown
2Duration of action of stationary object
If sequential shutdown process is performed to preserve machinery, then system longevity is extended, but shutdown time increases
Solution Approach 1:
The controller is pre-programmed with the optimal shutdown sequence, and isolation valves are positioned to automatically close specific hydraulic lines first. This preliminary arrangement ensures that when shutdown is initiated, the most critical protective actions occur immediately, reducing the overall time required for the sequential process
3Stability of the object's composition
If hydraulic pressure is maintained during shutdown, then boom position is secured, but risk of hydraulic line damage increases
Solution Approach 1:
The hydraulic system is divided into multiple isolated sections through isolation valves positioned at strategic locations. When shutdown occurs, these valves close specific hydraulic lines segment by segment, allowing pressure to be maintained in sections that need to hold position while safely releasing pressure from sections that would otherwise be damaged by sudden decompression
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
Ensures a safe and controlled shutdown of hydrovac operations, protecting the operator and machinery by preventing sudden system failures and extending component lifespan.
Implementation Method 1
a blower operatively connected to the debris tank and operative to create a vacuum in the debris tank
Implementation Method 2
maintaining hydraulic pressure to secure the boom position
Data Source
AI summary
A hydrovac is provided having, an engine, a transmission comprising a power take-off connected to a hydraulic pump, a debris tank, a vacuum hose connected to the debris tank, a boom carrying the vacuum hose, a blower operative to create a vacuum in the debris tank, a hydraulic motor connected to the blower to drive the blower, the hydraulic motor connected to the at least one hydraulic pump, an emergency shutoff valve connected in fluid communication with the debris tank, a boom isolation assembly which in a closed position fluidly isolates the debris tank from the vacuum hose, and a controller. A controller operative to, in response to the controller losing communication with a remote control, open the emergency shutoff valve, close the boom isolation assembly, disengage the power take-off, and after the power take-off is disengaged, slowing a speed of the engine to an idle speed.