Hydraulic Shovel Load Estimation With Fewer Weight Sensors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
As the number of sensors required to detect the weight of earth and sand in the bucket increases, the cost of the shovel also increases.
Innovation Solution
A shovel that calculates the weight of the loaded matter with a reduced number of sensors by utilizing a hydraulic system and control valves to estimate the weight based on the thrust of the boom cylinder and the center of gravity of the earth and sand.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensors are used to detect the weight of earth and sand in the bucket, then the measurement precision is improved, but the device complexity and cost increase
Solution Approach 1:
The patent extracts the weight detection function from multiple sensors and concentrates it into a single sensor that measures the thrust force of the boom cylinder. By measuring the thrust force and using torque balance calculations, the system determines the weight of earth and sand in the bucket without requiring multiple direct weight sensors, thus reducing device complexity while maintaining measurement precision
Solution Approach 2:
The patent introduces the thrust force of the boom cylinder as an intermediary parameter to indirectly measure the weight of earth and sand. Instead of directly measuring weight with multiple sensors, the system measures the thrust force (an intermediate physical quantity) and calculates the weight through torque balance relationships, thereby reducing the number of sensors needed
2Measurement precision
If multiple sensors are used to detect the weight of earth and sand in the bucket, then the measurement precision is improved, but the cost increases
Solution Approach 1:
The patent extracts the weight detection function from multiple expensive sensors and implements it using a single sensor combined with torque balance calculations. This approach significantly reduces the bill of materials cost while maintaining the same level of weight detection accuracy, thereby improving ease of manufacture
Solution Approach 2:
The patent creates a virtual model of the boom system with torque balance equations that replicates the weight measurement function. Instead of using multiple physical sensors, the system uses computational modeling to calculate weight from thrust force measurements, reducing manufacturing cost while preserving measurement precision
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 solution allows for the calculation of the weight of the earth and sand with reduced sensor usage, thereby decreasing the cost of the shovel while maintaining the ability to detect the load accurately.
Implementation Method 1
a hydraulic system and control valves to estimate the weight based on the thrust of the boom cylinder
Implementation Method 2
a hydraulic system and control valves to estimate the weight based on the thrust of the boom cylinder
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A shovel that calculates the weight of loaded matter with a reduced number of sensors, is provided. The shovel includes an attachment attached to a revolving upper body; and a control device. The control device includes a center of gravity estimation part configured to estimate a center of gravity of the loaded matter loaded in the attachment, and a weight calculating part configured to calculate a weight of the loaded matter based on the estimated center of gravity of the loaded matter.