Shovel Controller Optimizing Boost Pressure via Position-Based Preload
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Solution Overview
Problem
The existing preload boost function in shovels with diesel engines and superchargers often results in wasted boost pressure increase when hydraulic load does not rapidly increase, leading to inefficient engine output and increased fuel consumption.
Innovation Solution
A shovel with a controller system that determines the necessity of the preload boost function based on the position of the back-hoe attachment, specifically the bucket pin, to adjust electric power generation and boost pressure accordingly, ensuring efficient engine output and reduced fuel consumption by anticipating hydraulic load increases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the preload boost function is executed by increasing electric power generation load before hydraulic load increase, then engine output can be smoothly increased while maintaining constant engine revolutions, but fuel consumption increases when hydraulic load does not rapidly increase
Solution Approach 1:
The system executes electric power generation as a preliminary action before hydraulic load increase to boost engine output in advance. This allows the engine to maintain constant revolutions during subsequent hydraulic operations, ensuring smooth power delivery. The preliminary electric load creates a buffer that prevents engine speed drops when hydraulic demands arise.
Solution Approach 2:
The system dynamically adjusts the execution of preload boost function based on real-time detection of hydraulic load increase patterns. When rapid hydraulic load increase is detected, the system activates electric power generation to boost output. When no rapid increase is detected, the system skips the electric power generation step, thereby adapting fuel consumption to actual operational needs while maintaining reliability when required.
2Power
If electric power generation is actively increased prior to hydraulic load increase, then boost pressure increases to maintain constant engine revolutions, but the boost pressure increase becomes wasted if hydraulic load does not rapidly increase
Solution Approach 1:
The control device continuously monitors hydraulic load conditions and uses this feedback to determine whether to execute the preload boost function. When the monitor detects that hydraulic load is not rapidly increasing, the control device suppresses electric power generation, preventing wasted boost pressure. This feedback mechanism ensures engine output is optimized according to actual operational demands rather than operating on fixed schedules.
3Speed
If the preload boost function is executed without condition, then engine responsiveness to hydraulic load is improved, but fuel consumption increases unnecessarily
Solution Approach 1:
The system transitions from static, unconditional execution of preload boost to dynamic, condition-based execution. The control device adapts the timing and execution of electric power generation based on real-time detection of hydraulic load increase patterns, maintaining engine responsiveness only when operationally necessary rather than operating on fixed schedules.
Solution Approach 2:
The system changes the operational parameters of the preload boost function based on detected hydraulic load conditions. When rapid hydraulic load increase is detected, the system activates electric power generation with specific power levels. When no rapid increase is detected, the system modifies parameters to skip or reduce electric power generation, thereby optimizing fuel consumption while maintaining responsiveness when required.
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 executes the preload boost function only when necessary, maintaining constant engine revolutions and reducing fuel consumption by optimizing boost pressure and power generation in response to hydraulic load changes.
Implementation Method 1
a diesel engine provided with a supercharger
Implementation Method 2
a diesel engine provided with a supercharger is installed
Implementation Method 3
electric power generation by a power generator connected to the engine
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A shovel according to an embodiment of the present invention includes an attachment including a boom (4); a diesel engine (11) provided with a supercharger; a main pump (14) connected to the diesel engine (11) provided with the supercharger; a controller (30) that executes a preload boost function, wherein the preload boost function is for increasing boost pressure of the supercharger prior to increasing a hydraulic pressure load on the main pump (14). A range accessible by a predetermined part of the attachment includes a partial range at which, upon the boom (4) being operated, the preload boost function is to be executed and a partial range at which, upon the boom (4) being operated, the preload boost function is not to be executed.