Loader Bucket Rollback Control via Hydraulic Pressure Feedback
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Solution Overview
Problem
The efficiency of loading operations in construction vehicles, such as loaders, is reduced due to incomplete bucket loading, as the movement of the loader is stopped before the bucket is fully loaded with material.
Innovation Solution
A rollback control system that utilizes vehicle conditions data, including hydraulic pressure and acceleration, to determine the bucket's position relative to the material and outputs control signals to hydraulic cylinders to assist in fully loading the bucket by leveraging inertia forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the loader movement is stopped before the bucket is fully loaded, then the control simplicity is maintained, but the loading efficiency deteriorates due to incomplete bucket loading
Solution Approach 1:
The control system continuously monitors hydraulic pressure and acceleration data from sensors, comparing real-time values against threshold criteria to dynamically determine bucket loading status. This closed-loop feedback mechanism enables automatic detection of optimal loading points without requiring complex mechanical stop devices, thereby improving loading efficiency while maintaining control simplicity.
Solution Approach 2:
The patent replaces traditional mechanical bucket stop mechanisms with an electronic control system that uses hydraulic pressure sensors and acceleration data to determine loading completion. This substitution eliminates complex mechanical components while achieving more precise and adaptive loading control, directly addressing the contradiction between productivity improvement and device complexity.
2Quantity of substance
If the bucket is moved to load fully with material, then the loading efficiency improves, but the time required for loading increases
Solution Approach 1:
The control system pre-establishes threshold criteria for hydraulic pressure and acceleration that indicate optimal loading conditions. By preparing these decision boundaries in advance, the system can rapidly determine when the bucket is sufficiently loaded without requiring extended monitoring or complex real-time calculations, thus achieving full loading while minimizing loading time.
Solution Approach 2:
The system monitors changes in hydraulic pressure and acceleration parameters to detect the transition point when the bucket becomes fully loaded. By tracking parameter dynamics rather than relying on fixed positional markers, the system achieves complete material loading in optimized time, resolving the contradiction between loading quantity and loading duration.
3Manufacturing precision
If the bucket position is determined without precise measurement, then the system complexity is reduced, but the loading precision deteriorates resulting in incomplete loading
Solution Approach 1:
The patent introduces hydraulic pressure as an intermediary parameter that indirectly reflects bucket loading status. Rather than directly measuring bucket position or material volume, the system uses hydraulic pressure sensors to detect the resistance encountered during bucket movement, which correlates with loading completion. This intermediary approach achieves high loading precision while avoiding complex direct measurement systems.
Solution Approach 2:
The system replaces complex mechanical position sensing devices with hydraulic pressure sensors and acceleration data processing. This substitution maintains high loading precision by leveraging the physical relationship between hydraulic pressure and bucket loading state, while significantly reducing the complexity of the measurement system through the use of existing sensor infrastructure.
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 ensures the bucket is fully loaded in a shorter time, enhancing the efficiency of the loading operation by enabling precise control of the bucket's movement and utilizing inertia to retain loaded material.
Implementation Method 1
a source of pressure data that indicates a pressure associated with the hydraulic circuit
Implementation Method 2
a source of acceleration data associated with the boom assembly
Implementation Method 3
outputs one or more control signals to direct flow of hydraulic fluid to the hydraulic cylinders to move the bucket
Implementation Method 4
utilizing inertia to retain loaded material
Data Source
AI summary
A rollback control system and method are disclosed for a loader having a bucket movable between first and second positions by one or more hydraulic cylinders of a hydraulic circuit. The rollback control system includes a source of vehicle conditions data that indicates one or more observable conditions associated with the work vehicle. The rollback control system includes at least one controller that receives and processes the vehicle conditions data to determine a position of the bucket relative to a material. The at least one controller outputs one or more control signals to direct flow of hydraulic fluid to the hydraulic cylinders to move the bucket to the second position based on the determined position of the bucket.