Torque Load Control System for Stalling Prevention
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Solution Overview
Problem
Existing machine control systems are inefficient in preventing stalling by setting torque load limits, often due to delayed response times and inaccuracies in torque readings, which can lead to machine downtime and decreased efficiency.
Innovation Solution
A torque load control system that determines torque limits based on requested torque and additional machine operating parameters, using a torque error estimator to compensate for errors and maintain the torque producing system at a target operating speed by controlling torque consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If speed or acceleration based control systems are used to control machine operation, then stalling may be avoided, but the response time is delayed and efficiency decreases
Solution Approach 1:
The patent replaces speed/acceleration based control with torque based control. The controller directly monitors torque load requests from powered devices and compares them against available torque from the power source, enabling immediate detection and correction of torque imbalances before speed degradation occurs. This substitution of control basis eliminates the delayed response inherent in speed-based systems.
2Reliability
If limits are set based on inaccurate readings or values, then the effectiveness of those limits in preventing stalling is reduced
Solution Approach 1:
The patent implements a feedback mechanism where the controller continuously monitors both the torque load requests from powered devices and the actual torque output from the power source. By comparing requested torque against available torque in real-time, the system detects discrepancies and adjusts limits dynamically. This feedback loop compensates for measurement inaccuracies by continuously validating actual system state against expected values.
3Reliability
If torque load limits are set to prevent stalling, then power source speed is maintained, but machine operation efficiency decreases due to conservative limits
Solution Approach 1:
The patent implements dynamic torque load limiting where the controller continuously adjusts torque limits based on real-time power source capabilities and load requests. Rather than applying fixed conservative limits, the system dynamically optimizes torque allocation among powered devices, allowing maximum efficient operation while preventing stalling. The limits adapt to changing operating conditions, maintaining power source speed within acceptable ranges without unnecessarily restricting productive output.
Data Source
AI summary
A machine may include a torque producing system, and a torque consuming device including load controls operable to generate a request for torque. The machine may also include a control system coupled to the torque producing system and the load controls. The control system may be operable to receive the request for torque, determine a torque limit based on the requested torque, and communicate the torque limit to the load controls, the load controls being operable to adjust operation of the torque consuming device based on the torque limit.