Remote Hydraulic Tuning With Real-Time Pressure Feedback
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Solution Overview
Problem
Traditional methods for tuning hydraulic circuits, such as those in large mining machines, are hazardous, time-consuming, and inefficient, requiring technicians to manually adjust valves and pumps in high-pressure, high-temperature environments without access to real-time data.
Innovation Solution
A system comprising a controller, sensors, and actuators that allows remote hydraulic tuning through a software application on a mobile device, enabling technicians to adjust valve pressures and monitor flow rates and temperatures from a safe distance, using sensors for real-time data feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If technicians manually adjust valves and pumps in high-pressure hydraulic circuits, then hydraulic tuning can be performed, but the technicians are exposed to hazardous conditions including high pressure, high temperature, and moving machinery
Solution Approach 1:
The patent replaces manual mechanical adjustment with an automated system comprising a controller, actuators, and sensors. The controller receives input signals and automatically controls actuators to adjust hydraulic valves and pumps, eliminating the need for technicians to physically access high-pressure zones while maintaining tuning capability
Solution Approach 2:
The patent introduces a controller as an intermediary between the operator and the hydraulic system. The controller processes input signals and generates appropriate control signals for actuators, serving as a safe mediator that eliminates direct human exposure to hazardous high-pressure hydraulic components
2Productivity
If technicians perform manual hydraulic tuning, then adjustments can be made, but the process is time-consuming and inefficient
Solution Approach 1:
The patent implements a self-service system where the controller automatically performs hydraulic tuning based on received input signals. The system autonomously adjusts valves and pumps through actuators without requiring continuous manual intervention, significantly reducing tuning time and improving productivity
Solution Approach 2:
The patent enables continuous monitoring and adjustment through sensors that constantly measure hydraulic parameters and feed data to the controller. This continuous feedback loop allows for real-time optimization of hydraulic system performance, eliminating the intermittent nature of manual tuning
3Reliability
If technicians manually increase pressure using loading valves, then hydraulic flow testing can be performed, but the technicians are positioned near high-pressure circuits creating significant safety risks
Solution Approach 1:
The patent replaces manual pressure control during testing with automated actuator control. The controller receives test parameters and automatically adjusts loading valves through actuators, eliminating technician exposure to high-pressure zones while maintaining precise pressure control capability
Solution Approach 2:
The patent implements feedback control during pressure testing where sensors continuously monitor pressure and flow parameters, and the controller automatically adjusts actuators to maintain desired test conditions. This closed-loop system eliminates the need for technicians to manually monitor and adjust high-pressure conditions
Data Source
AI summary
In one aspect, a system (110) for performing an action is disclosed. In one arrangement and embodiment, the system (110) comprises: a tool (118) operable to perform at least the action; a controller (122); storage (124) storing electronic program instructions for controlling the controller (122); and an input/output means (126). In one form, the controller (122) is operable, under control of the electronic program instructions, to: receive input via the input means; process the input, and on the basis of the processing, control the tool to perform the action. In one embodiment, the action comprises a hydraulic tuning action in respect of a system, such as a hydraulic pump (114), comprising a hydraulic circuit.