Remote Hydraulic Tuning With Sensor-Guided Actuator Control
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Solution Overview
Problem
Traditional methods for hydraulic circuit tuning in high-pressure environments, such as those found in large mining machines, are hazardous, time-consuming, and inefficient, requiring technicians to physically access control rooms to adjust valves and pumps, exposing them to risks like burns and hydraulic injection, and lacking real-time data access.
Innovation Solution
A system comprising a controller, sensors, and actuators connected via a mobile device app that allows remote hydraulic tuning, enabling technicians to adjust valve pressures and monitor flow rates and temperatures from a safe distance, using a software application to automate adjustments based on real-time data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If technicians physically access control rooms to adjust valves and pumps, then hydraulic tuning can be performed, but technicians are exposed to hazardous environments with risks like burns and hydraulic injection
Solution Approach 1:
The patent replaces manual mechanical adjustment with an automated system comprising a processor, memory storing instructions, and an actuator. The processor executes instructions to automatically adjust hydraulic components based on sensor data, eliminating the need for technicians to physically access hazardous control rooms while maintaining tuning capability
Solution Approach 2:
The patent introduces an intermediary automated control system that acts as a mediator between the technician (who remains in a safe location) and the hydraulic components (in the hazardous control room). The actuator serves as the physical intermediary that performs adjustments remotely, while the processor and memory provide intelligent control without human exposure to danger
2Productivity
If technicians manually adjust valves using hand tools, then hydraulic tuning can be performed, but the process is time-consuming
Solution Approach 1:
The patent replaces slow manual mechanical adjustment with automated actuator-driven adjustment. The actuator, controlled by the processor executing instructions from memory, can rapidly adjust hydraulic components without the time constraints of manual operation, significantly increasing tuning productivity
Solution Approach 2:
The patent implements a self-service automated tuning system where the processor autonomously determines adjustment parameters based on sensor data and executes adjustments without continuous human intervention. This eliminates the time loss associated with manual technician operations while maintaining precise control
3Loss of information
If technicians physically monitor pressure gauges and flow meters, then real-time data can be obtained, but technicians must be present in hazardous locations
Solution Approach 1:
The patent replaces manual visual monitoring of pressure gauges and flow meters with electronic sensors that automatically detect and transmit hydraulic parameters to the processor. This substitution eliminates the need for technicians to physically observe instruments in hazardous locations while maintaining real-time data acquisition
Solution Approach 2:
The patent introduces electronic sensors as intermediaries between the hydraulic system and the technician. These sensors are positioned in the hazardous control room to collect real-time data, while transmitting information to the processor that can be accessed remotely by technicians in safe locations, eliminating direct exposure to high-pressure circuits
Data Source
AI summary
In one aspect, an actuator for actuating a device comprises driving means adapted to be operatively connected to the device, and operable to receive a reaction element for engaging the device. The driving means further comprises an output adapted to be operatively engaged with the device for actuation of the device whilst the reaction element is engaging the device.