Loader Float Control via Hydraulic Pressure Feedback
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Solution Overview
Problem
Conventional loader hydraulic systems face challenges in accurately controlling the float function, particularly when using accumulators, as they often result in uneven leveling and require manual adjustment to maintain the bucket's weight on the ground without additional pressure.
Innovation Solution
A control system with a three-chambered hydraulic cylinder, pressure sensors, an accumulator, and a controller that receives operator inputs to raise, lower, or float the bucket, calculating forces and adjusting hydraulic pressure to maintain the bucket's weight on the ground by controlling the hydraulic pump and valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an accumulator is used in the hydraulic system to store pressurized fluid, then the system can maintain pressure and improve float function, but the accumulator creates additional force on the cylinder chambers that complicates precise control of the bucket's weight on the ground
Solution Approach 1:
The system uses pressure sensors in each chamber of the three-chambered hydraulic cylinder to detect hydraulic pressure. The controller receives these pressure signals and calculates the forces acting on the boom, then adjusts the hydraulic pump and control valves to maintain the desired float condition where the bucket applies only its weight to the ground without additional pressure.
Solution Approach 2:
The patent replaces conventional mechanical float control with an electronically controlled hydraulic system. The controller electronically processes pressure sensor signals and automatically adjusts hydraulic pressure through electrically controlled valves and pump, substituting manual mechanical adjustment with automated electronic control.
2Ease of operation
If manual adjustment is used to maintain bucket weight on the ground, then the float function can be achieved, but it requires continuous operator intervention and results in uneven leveling
Solution Approach 1:
The system performs self-adjustment of hydraulic pressure to maintain the float condition. The controller continuously monitors pressure sensor feedback and automatically adjusts the hydraulic pump and control valves to counteract forces from the accumulator and maintain the bucket's weight on the ground, eliminating the need for continuous manual operator intervention.
Solution Approach 2:
Pressure sensors provide continuous feedback on the hydraulic pressure in each chamber. The controller uses this feedback to calculate the forces acting on the boom and automatically adjusts the hydraulic system to maintain precise control, ensuring even leveling without manual intervention.
3Manufacturing precision
If the bucket is allowed to float with only its weight on the ground, then smooth leveling is achieved, but the accumulator's stored pressure can cause the boom to move upward unexpectedly
Solution Approach 1:
The controller proactively counteracts the force from the accumulator before it can cause unexpected boom movement. By continuously monitoring pressure sensor feedback and calculating the accumulator's force on the cylinder chambers, the controller预先 applies opposing hydraulic pressure through the pump and control valves to maintain boom position stability.
Solution Approach 2:
The system uses real-time pressure feedback from sensors in each chamber to detect and counteract forces that would cause boom movement. The controller continuously adjusts hydraulic pressure to balance the accumulator's force, maintaining stable boom position and smooth leveling.
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 precise control of the bucket's position, ensuring it floats on the ground with only its weight, providing a smooth and even surface by automatically adjusting hydraulic pressure to counteract forces, thus improving leveling operations.
Implementation Method 1
an accumulator adapted to receive and store pressurized hydraulic fluid from at least one of three chambers of the hydraulic cylinder when the boom is lowered and supply pressurized hydraulic fluid to at least one of the three chambers of the hydraulic cylinder when the bucket is raised
Implementation Method 2
a plurality of pressure sensors adapted to measure a hydraulic pressure in each the three chambers of the hydraulic cylinder and output a plurality of corresponding signals
Implementation Method 3
controlling the hydraulic pump and the control valve to supply pressurized hydraulic fluid to another chamber of the cylinder to overcome the first force
Data Source
AI summary
The present invention is related to a loader of a construction apparatus such as front-end wheel loader or an agricultural tractor. Specifically, the present invention is related to a control system for a loader.