Thick Matter Pump Reversal Control via Sensor Feedback

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Solution Overview

Problem

Single-circuit two-cylinder thick matter pumps experience interruptions and noise due to variations in material consistency and pressure, leading to unreliable and undamped pipe switch reversal.

Innovation Solution

Implementing a computer-assisted control system that monitors both the drive cylinder pistons and pipe switch, using position and pressure sensors to adjust the reversible pump's flow and direction, and incorporating a reversing element in the pipe switch's hydraulic branch for controlled and cushioned reversal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the pipe switch is reversed using a separate pressure accumulator, then the reversal is reliable and shock-damped, but the device complexity increases

Engineering Contradiction:

Improvereliability of pipe switch reversalVSAvoidhydraulic circuit complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the pipe switch reversing function with the existing hydraulic circuit of the drive cylinder by branching off pressure fluid from the reversible pump. This merging eliminates the need for a separate pressure accumulator while maintaining reliable and shock-damped reversal operation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The hydraulic circuit is designed to serve multiple functions: it acts as the drive circuit for the conveyor cylinders and simultaneously provides the pressure fluid for reversing the pipe switch. This multi-functionality reduces overall system complexity while maintaining reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Device complexity

If the pipe switch is reversed in a single-circuit pump with direct pressure branching, then the device complexity is reduced, but interruptions and banging noises occur due to lack of shock damping

Engineering Contradiction:

Improvehydraulic circuit complexityVSAvoidbanging noises and interruptions

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The patent applies beforehand cushioning by using the existing hydraulic pressure fluid to dampen the shock during pipe switch reversal. The hydraulic system naturally cushions the impact before it occurs, preventing banging noises and interruptions while maintaining a simple single-circuit design.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Productivity

If the piston speed is maintained at high velocity, then the productivity is improved, but the piston impacts the cylinder end with high force causing noise and potential damage

Engineering Contradiction:

Improveconveyance speedVSAvoidimpact noise and mechanical stress

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent implements periodic action by reversing the flow direction of the reversible pump at regular intervals corresponding to the piston stroke cycle. This periodic reversal allows the piston to maintain high velocity during the conveyance phase while being decelerated smoothly during the reversal phase, reducing impact noise and mechanical stress.

Inventive Principle:

Principle #19Periodic action

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

Ensures reliable and quiet operation of single-circuit two-cylinder thick matter pumps by monitoring and adjusting the pipe switch's pivot position and piston movement, reducing noise and interruptions during material conveyance.

Implementation Method 1

hydraulic drive cylinders controlled by a hydraulic reversible pump

Methodology Applied

Scientific EffectHydraulic pressure transmission: Hydraulic Press

Implementation Method 2

the pipe switch includes a position indicator sensing its pivot position, of which the output signal is a measure for the pivot angle of the pipe switch

Methodology Applied

Scientific EffectPosition sensing:

Implementation Method 3

at least two cylinder switch sensors are provided spaced apart from each other on the drive cylinders, sensing the pistons of the drive cylinders as they pass by

Methodology Applied

Scientific EffectPosition detection:

Implementation Method 4

a pressure sensor is provided sensitive to the pressure sequence at the high pressure output of the reversible pump

Methodology Applied

Scientific EffectPressure sensing:

Data Source

PatentUS7611332B2Device and method for controlling a thick matter pump

Publication Date: 2009.11.03 PUTZMEISTER ENG GMBH

AI summary

A device and a method for controlling a two-cylinder thick matter pump to achieve a reliable operation even of single-circuit two-cylinder thick matter pumps. To this end, the pipe switch includes a position transmitter responding to the pivoting position. At least two cylinder switching sensors are arranged on the working cylinders at a distance from each other, responding to the passing pistons of the drive cylinder, and/or a pressure sensor responding to the pressure course at the high-pressure outlet of the reversible pump is provided. A computer-assisted reversing device has a control routine responding to output signals of the position transmitter and to output signals of the cylinder switching sensors and/or the pressure sensors, enabling the programmed control of a control body for adjusting the flow quantity and direction of the reversible pump, and a reversing element arranged in the hydraulic branch of the pipe switch.