Instrumented Wear Elements for Earth Moving Machinery Force Measurement
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Solution Overview
Problem
Current systems for measuring forces on wear elements in earth moving machinery rely on theoretical simulations, which are often overengineered due to lack of accurate real data, leading to inefficiencies and increased risk of wear element failure.
Innovation Solution
A system comprising sensors arranged in wear elements to measure real-time forces, pressures, and loads, allowing for accurate data collection and processing to optimize wear element design and machine operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If theoretical simulations are used to determine mechanical requirements, then design criteria can be established, but the measurements are inaccurate and lead to overengineering
Solution Approach 1:
The patent replaces complex theoretical mechanical simulations with direct physical measurements using sensors (strain gauges, load cells, piezoelectric sensors) embedded in wear elements. This substitution provides accurate real-time force data without requiring complex computational models, resolving the contradiction between measurement accuracy and system complexity.
Solution Approach 2:
The measurement system utilizes the wear elements themselves as part of the sensing mechanism. The wear elements are instrumented with sensors that directly measure the forces they experience during operation, eliminating the need for separate measurement apparatus and reducing overall system complexity while maintaining high measurement accuracy.
2Reliability
If wear elements are overengineered to withstand maximum stresses, then reliability increases, but productivity decreases due to inefficiency
Solution Approach 1:
The patent implements a feedback system where real-time force measurements from sensors in wear elements are continuously monitored and fed back to the control system. This allows dynamic adjustment of machine operation parameters to optimize performance while preventing excessive loads, thereby maintaining both high reliability and productivity without overengineering.
Solution Approach 2:
The system transitions from static overengineered design to dynamic adaptive operation. By continuously measuring actual forces and adjusting operational parameters in real-time, the system optimizes wear element utilization, ensuring they operate within safe limits while maximizing excavation efficiency, thus improving productivity without sacrificing reliability.
3Measurement precision
If sensors are installed in wear elements to measure real forces, then measurement accuracy improves, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into the wear elements: they serve both as protective/ground-engaging components and as force-sensing elements. The sensors embedded in wear elements allow these components to simultaneously perform their mechanical function and provide measurement data, eliminating the need for separate measurement apparatus and reducing overall system complexity.
Solution Approach 2:
The patent merges the wear element structure with the sensing system by embedding sensors directly within the wear elements. This integration combines the mechanical protection function with the measurement function in a single component, reducing the number of separate parts and simplifying the overall system while maintaining high measurement accuracy.
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 system enables more efficient earth moving operations by accurately determining mechanical requirements, reducing wear element failure risk, and optimizing machine performance, leading to improved productivity and cost-effectiveness.
Implementation Method 1
one or more sensors for measuring forces (for example, strains or unitary deformations), each sensor of the one or more sensors being arranged in one wear element of the plurality of wear elements or between two wear elements of the plurality of wear elements
Data Source
AI summary
System (1-3) for earth moving machinery (100), comprising: a plurality of wear elements (10-15) adapted for coupling with a blade (111) of digging implements (110) of an earth moving machine (100); one or more sensors (20) for measuring forces, each sensor of the one or more sensors (20) being arranged in one wear element of the plurality of wear elements (10-15) or between two wear elements of the plurality of wear elements (10-15); and central control means (50) for processing measurements of the one or more sensors (20) in order to calculate force withstood by the wear elements (10-15).