Articulated Mast Speed Limiting for Fast Fold-Unfold Operation
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Solution Overview
Problem
Existing large manipulators, such as truck-mounted concrete pumps, inefficiently utilize the permitted speed of the articulated mast tip due to speed limitations, leading to slow unfolding and folding times, and lack effective manual control to ensure compliance with legal speed limits in emergency operations.
Innovation Solution
The control device limits mast movement speed based on sensor system outputs, with manual control options that include mechanical and electronic limiting means to ensure the mast speed does not exceed legal limits, allowing for higher speeds in normal operations and safe manual control in emergencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the control valves are configured to limit the mast tip speed to the legally permitted maximum in all positions, then safety compliance is ensured, but the operational efficiency is significantly reduced due to unnecessary speed restrictions
Solution Approach 1:
The control system dynamically adjusts the speed limits based on the current mast position and configuration. The control device receives position data from sensors and automatically modifies the permitted speed of the mast tip according to the actual operational state, allowing higher speeds when safe and maintaining legal limits when necessary
Solution Approach 2:
The system changes the speed parameter dynamically based on mast position parameters. Different speed limits are applied depending on whether the mast is in extended, retracted, or intermediate positions, optimizing the balance between safety and efficiency for each operational state
2Productivity
If the control valves are configured to allow higher speeds for faster operation, then productivity is improved, but the risk of exceeding legal speed limits increases
Solution Approach 1:
The control system continuously receives feedback from sensors about the mast position, extension state, and current speed. Based on this feedback, the control device automatically adjusts the speed commands to ensure legal compliance while maximizing operational efficiency, preventing excessive speeds before they occur
3Loss of time
If manual control is allowed in emergency operations without speed limits, then response time is reduced, but the risk of unsafe operations increases
Solution Approach 1:
The system pre-configures emergency control modes with built-in safety mechanisms. Before manual emergency control is activated, the system prepares appropriate speed limits and safety parameters based on the current mast position, ensuring that even in emergency mode, operations remain within safe boundaries while maintaining rapid response capability
Data Source
AI summary
A large manipulator includes a chassis, a turntable arranged on the chassis and rotatable around a vertical axis via a rotary drive, and an articulated mast including two or more mast segments pivotably-movably connected, via articulated joints, with the respectively adjacent turntable or mast segment via a respective drive. The large manipulator further includes a mast sensor system configured to detect position of at least one point of the articulated mast or a pivot angle of at least one articulated joint and configured to generate sensor output signals. The large manipulator further includes a control device configured to actuate the drive in a normal operation for mast movement and to limit speed of movement of the articulated mast depending upon the sensor output signals. The drive is manually controllable in an emergency operation. The large manipulator further includes at least one limiting means, which, in the emergency operation, limit speed of the drive to a pre-specified maximum value.