Loadpin Active Biasing for Wear and Thermal Drift Compensation
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Solution Overview
Problem
Loadpin measurements in industrial machines are affected by wear and tear, temperature fluctuations, leading to accuracy deviations that impact the operation of these machines.
Innovation Solution
A system and method for actively biasing loadpins using a power shovel positioning module, loadpin bias module, and active bias determination module, which determine the operational condition of the machine and calculate loadpin bias values based on kinematic models and sensor signals to compensate for measurement deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If loadpin measurements are used in industrial machines, then the machine can calculate load weight, but measurement accuracy deteriorates due to wear and tear and temperature fluctuations
Solution Approach 1:
The system continuously monitors loadpin signals and compares them against expected values based on machine kinematics. When deviations are detected (indicating drift or wear), the system automatically calculates correction factors and applies them to compensate for the inaccuracies, creating a closed-loop feedback mechanism that maintains measurement precision
Solution Approach 2:
The system dynamically adjusts measurement parameters by applying correction factors to the loadpin signals. These correction factors modify the electrical signals from the loadpin to compensate for thermal drift and wear-related deviations, effectively changing the measurement parameters to maintain accuracy under varying conditions
2Measurement precision
If correction factors are applied to loadpin signals, then measurement accuracy improves, but system complexity increases
Solution Approach 1:
The system performs self-calibration by using its own operational data (kinematic model outputs, resolver signals) to generate correction factors. The control system automatically monitors its own performance and adjusts the measurement signals without requiring external calibration equipment or manual intervention, making the complexity self-managing
Solution Approach 2:
The control system performs multiple functions: it controls machine operations, monitors sensor signals, calculates kinematic positions, generates correction factors, and applies compensations. By consolidating these diverse functions into a single control system, the patent avoids adding separate complex subsystems for each function
Data Source
AI summary
Systems and methods for actively biasing a loadpin. The systems include, for example, a power shovel positioning module, a loadpin bias module, and an active bias determination module. The power shovel positioning module is configured to determine the position of one or more components of an industrial machine. The loadpin bias module is configured to generate a signal associated with a vector quantity (e.g., having a magnitude and a direction) which can be used to describe the force applied to the loadpin in both an x-direction and a y-direction. The active bias determination module is configured to determine whether the industrial machine is in a proper state or condition to actively bias the loadpin, and determine loadpin bias values during the operation of the industrial machine when the industrial machine is in the proper condition for loadpin biasing.