Quick Coupler Dual-Channel Control to Prevent Inadvertent Tool Release
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Solution Overview
Problem
Existing quick coupler systems in earth moving equipment lack sufficient safety measures to prevent inadvertent events during tool exchange, despite efforts to improve safety, as they are prone to single-point failures and operator misuse.
Innovation Solution
A control device with a three-state switch and electro-valve configuration, utilizing hardwire and logically controlled channels to prevent common mode failures, along with visual and audio warnings, and an armrest position sensor to ensure intentional operation, thereby requiring multiple failures for undesirable events to occur.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional quick coupler system with single control line is used, then the ease of operation is improved, but the reliability deteriorates due to single-point failures
Solution Approach 1:
The control system is segmented into two independent control lines (first control line and second control line) that both must be activated simultaneously to enable disengagement. This segmentation prevents single-point failures from causing inadvertent tool exchange, as both control lines must fail together for the system to malfunction.
Solution Approach 2:
A control unit acts as an intermediary between the three-state switch and the electro-valve, processing signals from two different end positions (first end position and second end position) before activating the disengagement mechanism. This intermediary layer adds logical control to prevent common mode failures.
2Reliability
If a three-state switch with dual control lines is implemented, then the reliability is improved by preventing common mode failures, but the device complexity increases
Solution Approach 1:
The three-state switch performs multiple functions: it provides neutral position (middle end position) for normal operation, first end position for initiating disengagement sequence, and second end position for confirming disengagement command. This multi-functionality consolidates what could be multiple separate controls into a single integrated component.
Solution Approach 2:
The control unit merges the control logic for both control lines into a single processing element, and the electro-valve merges both control line inputs into a single actuation mechanism. This combining approach reduces overall system complexity despite adding control lines.
3Reliability
If both terminals of the electro-valve coil are selectively controlled, then the resistance to faults is improved, but the manufacturing complexity increases
Solution Approach 1:
The system replaces traditional mechanical control (single control line with mechanical switches or valves) with an electro-hydraulic control system using an electro-valve and control unit. This substitution enables selective control of both coil terminals through electrical signals, improving fault resistance while maintaining manufacturing feasibility through standardized electro-hydraulic components.
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
Enhances safety integrity and resistance to faults, minimizing dependent failures and preventing operator misuse, ensuring safer tool exchange operations in earth moving equipment.
Implementation Method 1
a electro-valve coupled hydraulically to the disengaging actuator
Implementation Method 2
The quick coupler system is usually operated by hydraulic pressure
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
A control device and method for controlling a disengaging actuator (1) of a tool attachment, the device comprising a three-state switch (2), with a middle neutral position (20), a first end position (21), and a second end position (22), a control unit (3, 3'), having an input corresponding to an activation of the first end position (21), an electro-valve (4) coupled hydraulically to the disengaging actuator (1), having a coil (40), a first control line (41) and a second control line (42) coupled respectively to first and second terminals of the coil (40) of the electro-valve, wherein one of the first and second control lines is coupled to the second end position (22) of the three-state switch and the other of the first and second control lines is coupled to an output of the control unit, such that both control lines have to be activated to allow disengagement.