Loading Machine Drive Train Overload Protection
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Solution Overview
Problem
Existing loading machines face damage from overload conditions due to extreme torque moments in the drive train, which current overload protection systems address by using extensive and costly measurement devices to limit engine power.
Innovation Solution
A control unit determines critical operating conditions in the loading machine to indirectly assess drive train overload, allowing for preventive engine power limitation without the need for direct power flow measurements, using sensors like wire strain gauges, pressure sensors, and position sensors to adjust engine output and prevent overload.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If direct measuring devices are installed on the drive train to monitor overload conditions, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses an intermediary approach by measuring operating conditions (temperature, pressure, vibration, fuel consumption) that correlate with drive train load, rather than directly measuring torque or power flow. These intermediary measurements provide sufficient information to detect overload conditions without requiring complex direct measurement devices on the drive train.
Solution Approach 2:
The patent replaces mechanical measurement devices (torque sensors, power flow meters) with alternative sensing methods that measure environmental or operational parameters (temperature sensors, pressure sensors, vibration sensors, fuel consumption sensors). This substitution achieves overload detection with simpler, less intrusive measurement systems.
2Reliability
If engine power is limited preventively based on operating conditions, then drive train reliability is improved, but power output is reduced
Solution Approach 1:
The system performs preliminary action by proactively limiting engine power before actual overload damage can occur. By monitoring operating conditions and predicting potential overload scenarios, the system prevents damage by reducing power output in advance, rather than reacting after damage has occurred.
Solution Approach 2:
The patent implements dynamic power limitation that adjusts engine power output based on real-time operating conditions. The system continuously monitors temperature, pressure, vibration, and fuel consumption, and dynamically adjusts power limits accordingly, allowing maximum power when conditions are favorable and restrictive limits when conditions indicate potential overload risk.
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
This approach effectively prevents drive train overload by limiting engine power before critical conditions are reached, reducing the risk of damage and allowing for cost-effective axle constructions, utilizing existing vehicle components with minimal additional installation.
Implementation Method 1
using sensors like wire strain gauges, pressure sensors, and position sensors to adjust engine output and prevent overload
Data Source
AI summary
A loading machine is disclosed with at least one drive train, with at least one overload protection device for the drive train and with sensors for determining an overload state in the drive train. Critical operating conditions of the loading machine can be determined based on signals from the sensors, such that the load application on the drive train can be influenced in terms of power. The determination of critical operating conditions is implemented by means of a control unit which evaluates the signals from the sensors. When preset threshold values have been attained, the control unit generates control signals for a fuel injection pump, upon which a preventive limitation of the power is initiated.