Thick Matter Pump Reversal Control via Piston Speed
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Solution Overview
Problem
Existing thick matter pumps face challenges in completely emptying cylinders without piston banging or residual material due to delayed switching times in conventional reversible pumps, leading to incomplete emptying and potential hardening of concrete.
Innovation Solution
Implementing a computer-assisted switching device with measurement and evaluation routines that detect the piston's movement course between cylinder ends, calculating precise initiation times for the reversible pump and pipe switch based on piston speed and predetermined intervals, ensuring complete emptying and coordinated switching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional fixed-position cylinder switch sensors are used to trigger pump reversal, then the pump can operate with simple control logic, but the cylinder cannot be completely emptied when piston speed varies, leading to residual material and potential hardening
Solution Approach 1:
The patent applies dynamics by transitioning from fixed-position sensors to a dynamic control system that continuously monitors piston position and calculates optimal reversal timing based on real-time piston speed. The control unit adjusts the reversal trigger moment dynamically, ensuring complete cylinder emptying regardless of varying piston speeds or conveyance amounts.
Solution Approach 2:
The patent implements feedback by using sensors to continuously detect piston position and feeding this information back to the control unit. The control unit processes this feedback signal to calculate the precise moment for pump reversal, creating a closed-loop control system that adapts to varying operating conditions and ensures complete material discharge.
2Reliability
If the reversible pump switching is initiated too early based on fixed sensor positions, then complete cylinder emptying is achieved, but piston banging occurs at the cylinder base
Solution Approach 1:
The patent applies preliminary action by calculating and preparing the optimal reversal timing in advance based on detected piston speed and position. The control unit determines the precise moment to initiate pump reversal before the piston reaches the base, allowing the system to prepare for reversal while the piston is still moving, thereby preventing both incomplete emptying and piston banging.
Solution Approach 2:
The patent implements parameter changes by dynamically adjusting the pump reversal timing parameter based on real-time piston speed and position measurements. Instead of using a fixed timing parameter, the system continuously modifies the reversal trigger moment to optimize the balance between complete cylinder emptying and preventing piston impact at the base.
3Adaptability or versatility
If remote control varies the conveyance amount, then the pump becomes adaptable to different production requirements, but the fixed switching timing causes coordination problems between piston position and pump/pipe switch reversal
Solution Approach 1:
The patent applies dynamics by making the pump and pipe switch reversal timing dynamic rather than fixed. The control unit continuously monitors piston position and speed, and automatically adjusts the reversal trigger moment to match the actual piston movement characteristics, ensuring proper coordination regardless of conveyance amount variations.
Solution Approach 2:
The patent implements feedback by using piston position sensors to provide real-time information to the control unit, which then adjusts the reversal timing accordingly. This feedback mechanism ensures that the pump and pipe switch reversal remains coordinated with piston movement even when conveyance amounts are varied through remote control.
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
This solution allows for complete emptying of cylinders at each stroke without piston banging, ensuring efficient operation and preventing residual material, even when conveyance amounts are varied.
Implementation Method 1
a hydraulic reversible pump (6) and via these control hydraulic drive cylinders (5, 5')
Implementation Method 2
the passing-by of the piston is detected at each conveyor stroke in at least two sensor positions in predetermined spacing from each other and from the rod and/or bottom side end of the drive cylinder
Data Source
AI summary
The invention relates to a device and a method for controlling a two-cylinder thick matter pump comprising delivery pistons that are actuated in a push-pull manner by means of a hydraulic reversible pump (6) and hydraulic drive cylinders controlled by said pump. For each pressure stroke, the delivery cylinders (50, 50′) are connected to a delivery conduit (58) by means of a pipe junction (56). At the end of a pressure stroke, a reversal process of the reversible pump (6) and the pipe junction (56) is triggered. The aim of the invention is to obtain a targeted reversal of the reversal pump and the pipe junction, even when the deliverable quantity is varied, whereby the delivery cylinders are completely emptied, but also without pistons banging the ends of the cylinders. To this end, a computer-assisted reversal device is provided, said device comprising a measuring and evaluating routine for detecting the temporal displacement course of the piston along the path thereof between the two cylinder ends, by measurement and/or calculation, and for calculating a triggering time derived therefrom for the subsequent reversal of the reversible pump and the pipe switch.