Power Source Derating for Drive Train Protection
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Solution Overview
Problem
Existing systems for controlling power output in heavy machinery to prevent drive train component damage are inefficient and costly, often requiring additional sensors that can lead to under- or over-limitation of machine power, resulting in performance and cost issues.
Innovation Solution
A method that determines operational parameters of the power source and power conversion unit to select a derate value, reducing the power output to limit torque and prevent damage, using a control module to adjust the power curve based on torque converter speed ratio and engine speed, minimizing sensor usage and optimizing performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-defined power curves are used to limit torque in first gear, then drive train component damage is prevented, but machine performance efficiency deteriorates
Solution Approach 1:
The patent implements dynamic power derating by continuously monitoring torque converter speed ratio and engine speed to calculate real-time derate values, replacing static pre-defined power curves with adaptive power limitation that adjusts to actual operating conditions, thereby preventing component damage while maintaining optimal performance efficiency
Solution Approach 2:
The system changes the derate parameter from fixed gear-based values to dynamic values calculated from torque converter speed ratio and engine speed, allowing the power source to operate at optimal efficiency points while still limiting torque to protect drive train components
2Reliability
If additional sensors are added to detect overload conditions, then drive train monitoring capability is improved, but device complexity and production cost increase
Solution Approach 1:
The system uses existing sensors (torque converter speed sensor and engine speed sensor) that are already part of the machine's operational monitoring system, eliminating the need for additional strain gauges or overload sensors. The control module self-calculates torque conditions using readily available data, reducing device complexity while maintaining monitoring capability
Solution Approach 2:
The existing speed sensors serve dual purposes: monitoring machine operational parameters for normal control functions and providing data for torque overload detection. This multi-functional use of existing sensors eliminates the need for dedicated overload sensors, reducing system complexity
3Measurement precision
If ground speed sensors and strain gauges are used for overload detection, then overload state determination is improved, but machine performance suffers due to under- and over-inclusive power limitation
Solution Approach 1:
The system continuously monitors torque converter speed ratio and engine speed, using this feedback to dynamically adjust power derating in real-time. This closed-loop control ensures precise torque limitation only when actual overload conditions exist, preventing both under- and over-inclusive power limitation that would occur with static thresholds
Solution Approach 2:
The patent replaces static overload detection thresholds with dynamic calculations based on real-time torque converter speed ratio and engine speed, allowing the system to accurately identify true overload conditions across varying operating scenarios, thereby maintaining machine performance while preventing component damage
Data Source
AI summary
A method for derating a power source to limit damage to a drive train of a machine including determining a first operational parameter associated with a power conversion unit and a second operational parameter associated with the power source, selecting, based on the first operational parameter associated with the power conversion unit and the second operational parameter associated with the power source, a power source derate value, and reducing an available power output associated with the power source according to the derate value.