Hydraulic Jack Protector with Ultrasonic Stroke Monitoring
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Solution Overview
Problem
In the prestressing process of civil construction, there is a lack of an industrial marking system for prestressing cables, which complicates the positioning of these cables in a parabolic configuration, and there is no effective mechanism to prevent overloading of the hydraulic jack and track its usage.
Innovation Solution
An intelligent protector system for stretching ropes during prestressing, equipped with a power cut-off mechanism, a locator for a hydraulic jack, and sensors to monitor the jack's movement, along with a GPS module to track the equipment's location and usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual monitoring of hydraulic jack stroke is used, then operator control flexibility is maintained, but equipment overloading and operator safety are compromised
Solution Approach 1:
The system pre-establishes maximum stroke limits and automatically activates the power cut-off mechanism when these limits are approached, preventing overloading before it occurs. The GPS locator also pre-tracks equipment position to enable real-time monitoring without requiring complex manual intervention systems.
Solution Approach 2:
The ultrasonic sensor continuously measures the hydraulic jack stroke and provides real-time feedback to the control system. When the stroke approaches the pre-set maximum limit, the system automatically cuts off power to prevent equipment damage, creating a closed-loop safety mechanism that eliminates the need for complex manual monitoring.
2Loss of information
If GPS tracking and data collection systems are added, then equipment usage information is obtained, but device complexity and cost increase
Solution Approach 1:
The GPS module serves multiple functions simultaneously: it tracks the hydraulic jack's location in real-time, records equipment usage data, and enables productivity assessment. This multi-functionality reduces the need for separate dedicated systems for each function, thereby limiting the increase in overall device complexity while maximizing information collection.
3Reliability
If ultrasonic sensors and power cut-off mechanisms are implemented, then hydraulic jack overloading is prevented, but device complexity increases
Solution Approach 1:
The system replaces complex mechanical overload protection mechanisms with an ultrasonic sensing system that measures stroke distance and electronically controls power cut-off. This substitution uses non-contact sensing and electronic control instead of heavy mechanical linkages and physical limit switches, reducing mechanical complexity while improving reliability.
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 prevents overloading of the hydraulic jack, extends its operational life, enhances operator safety, and allows for the collection of data on equipment usage, facilitating productivity assessments and preventive maintenance.
Implementation Method 1
protector equipped with sensors to monitor the jack's movement
Data Source
AI summary
The present disclosure relates to an intelligent protector for stretching ropes in the prestressing process, having a power cutoff and a locator for a hydraulic jack, as well as to the use thereof. The present utility model patent application is applicable to the field of civil construction, especially to assistance during prestressing. The present invention streamlines the prestressing process by informing the operator of the maximum and minimum opening limit of the pistons, thus protecting the equipment, increasing its useful life, and avoiding breakages mid-operation. The invention also protects the operator from potential overload that can damage the equipment and put the operator at risk of injury.