Powertrain Vibration Control via Predictive Listening Window
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Solution Overview
Problem
Existing vibration control systems for machines struggle to differentiate between predictable engine vibrations and unpredictable external vibrations, leading to improper corrective measures that can worsen the vibrations experienced by operators, and fail to effectively manage vibrations induced by the powertrain.
Innovation Solution
A control system that includes sensors to classify machine operations into predetermined segments of a work cycle, predicts vibration profiles, tunes a listening window to capture powertrain-induced vibrations, and generates canceling vibrations using a vibration inducing device to mitigate these vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the system responds to all sensed vibrations including external vibrations, then the vibration cancellation may be generated, but it leads to improper corrective measures that actually worsen the vibrations experienced by the operator
Solution Approach 1:
The patent segments the vibration signal into different frequency components using Fast Fourier Transform (FFT). By analyzing the frequency spectrum, the system identifies and isolates powertrain-induced vibrations from external vibrations based on their characteristic frequency ranges. This segmentation allows the control system to selectively cancel only the harmful powertrain vibrations while ignoring external vibrations that cannot be effectively canceled.
Solution Approach 2:
The patent introduces an intermediary classification process that acts as a mediator between vibration sensing and cancellation actuation. The controller classifies each frequency component as either 'cancelable' (powertrain-induced) or 'non-cancelable' (external) before generating cancellation signals. This intermediary step prevents direct cancellation of external vibrations, avoiding the worsening of operator vibration exposure.
2Measurement precision
If the system uses a broad listening window to capture all vibrations, then more vibration types can be detected, but powertrain vibrations may be obscured by external vibration noise
Solution Approach 1:
The patent implements a dynamic listening window that adjusts its frequency range based on the current operating conditions of the powertrain. The controller continuously monitors engine speed and load conditions, then dynamically adjusts the frequency band of the listening window to track the varying frequency characteristics of powertrain vibrations. This dynamic adjustment maintains high detection accuracy while filtering out external vibration noise that falls outside the tracked frequency range.
Solution Approach 2:
The patent changes the parameters of the listening window (frequency range, bandwidth, center frequency) based on real-time powertrain operating parameters such as engine RPM and load. By adjusting these parameters dynamically, the system optimizes the signal-to-noise ratio for detecting powertrain vibrations without requiring overly complex signal processing algorithms, thus balancing measurement precision with manageable device complexity.
3Productivity
If the system generates canceling vibrations for external vibrations, then vibration reduction may be attempted, but the corrective measures are improper and worsen the vibrations
Solution Approach 1:
The patent converts the limitation of not being able to cancel external vibrations into a benefit by using frequency analysis to identify and exclude them from the cancellation process. The system recognizes that external vibrations have different frequency characteristics than powertrain vibrations, and uses this distinction to avoid generating harmful cancellation signals. This approach inadvertently protects operator comfort while still extending productive operating time through effective powertrain vibration cancellation.
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
The system effectively reduces powertrain-induced vibrations, improving operator comfort and extending operating time by accurately distinguishing and responding to powertrain vibrations while filtering out external vibrations, thereby enhancing stability and efficiency.
Implementation Method 1
generate a command wave that directs the vibration inducing device to generate canceling vibrations during the future segment
Data Source
AI summary
A vibration control system is disclosed for a machine having a powertrain secured by a mounting system. The control system may include a first sensor, a second sensor, a vibration inducing device, and a controller. The first sensor may be configured to generate a first signal indicative of a parameter of a work cycle of the machine, and the second sensor may be configured to generate a second signal indicative of vibrations induced by the powertrain. The controller may be in communication with the first sensor, the second sensor, and the vibration inducing device. The controller may be configured to classify a current operation of the machine as one of a plurality of predetermined segments of a work cycle based on the first signal, to predict a vibration profile that will be generated by the machine during a future segment of the work cycle, to tune a listening window based on the vibration profile, and to generate a command wave directed to the vibration inducing device to generate canceling vibrations during the future segments based on the second signal received within the listening window.