Pilot Hydraulic Control for Grade and Boom Precision
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Solution Overview
Problem
Existing construction machines with pilot operated hydraulics lack advanced electronic controls, limiting their precision and efficiency in operations such as grade control, electronic fencing, and intelligent boom control.
Innovation Solution
The integration of a control system that utilizes sensors to convert operator input into electrical signals, which are then processed by a controller to generate command signals for the hydraulic actuators, allowing for advanced precision construction features like grade control, electronic fencing, and intelligent boom control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If pilot operated hydraulics are used for manual control, then the machine structure remains simple and cost-effective, but advanced precision construction features such as grade control, electronic fencing, and intelligent boom control cannot be implemented
Solution Approach 1:
An electronic control system with sensors, controllers, and command signal generators is introduced as an intermediary layer between the operator and the hydraulic actuators. This intermediary electronic system enables precision construction features while the existing hydraulic system remains unchanged, thus adding adaptability without fundamentally altering the core hydraulic architecture.
Solution Approach 2:
The control valve manifold is designed to receive multiple types of input signals (manual hydraulic pilot signals and electronic command signals) and route them appropriately to control different actuators. This multi-functional capability allows the same hydraulic system to support both traditional manual operation and advanced precision construction features.
2Manufacturing precision
If electronic controls are added to existing pilot operated hydraulic machines, then precision and efficiency are improved, but system complexity and cost increase
Solution Approach 1:
The control system is segmented into independent functional modules: sensors for detecting operator input, controllers for processing signals, command signal generators for creating control commands, and a control valve manifold for signal distribution. This modular segmentation allows each component to be optimized for precision while keeping the overall system complexity manageable through standardized interfaces.
3Adaptability or versatility
If automated actuator control programs are implemented, then grade control and electronic fencing capabilities are achieved, but the control system becomes more complex
Solution Approach 1:
The controller receives electrical signals from sensors that detect operator input device positions and movements. This feedback mechanism enables the automated control program to continuously monitor operator intent and adjust actuator commands accordingly,实现ing grade control and electronic fencing capabilities through closed-loop control rather than complex open-loop programming.
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 solution enables construction machines to perform advanced precision operations, enhancing their precision and efficiency while maintaining compatibility with existing pilot operated hydraulic systems.
Implementation Method 1
Each of the operator input devices has associated therewith a sensor for generating an electrical signal corresponding to the direction and distance of movement of the operator input devices
Implementation Method 2
The controller is configured to receive the electrical signals and detect from the electrical signals the operator's input directing actuation of one or more of the actuators. The controller is further configured to generate one or more electrical command signals corresponding to a limited control actuation of one or more of the actuators
Implementation Method 3
A control valve manifold is configured to receive electrical command signals and to generate pilot hydraulic pressure output signals corresponding to the electrical command signals
Implementation Method 4
A pilot manifold is configured to receive the pilot hydraulic pressure output signals from the control valve manifold and direct the pilot hydraulic pressure output signals to one or more of the pilot operated main hydraulic control valves
Implementation Method 5
A pilot operated main hydraulic control valve is associated with each of the actuators
Data Source
AI summary
A pilot hydraulic system of a work machine is upgraded to include advanced productivity features such as automatic grade control, electronic fencing and intelligent boom control. The directions input by the human operator via joystick and foot pedal input devices may be sensed with pressure sensors mounted on the hydraulic pilot valves associated with the input devices. Electrical signals from the pressure sensors may then be processed by the automated control system. Electrical command signals from the control system may be converted back to hydraulic pilot pressure signals using electro-hydraulic proportional control valves. Those hydraulic pilot pressure signals then direct the main hydraulic control valves which control operation of the various actuators of the work machine thus superimposing on the operator input various actuator limitations determined by the automated control system.