Trencher Controller Maintains Constant Power Output
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Solution Overview
Problem
Trenchers experience a significant additional load on their power systems when the crawler speed exceeds the excavating element's speed, leading to reduced speed and increased pull force, which can cause the excavating element to stall, resulting in overheating and potential damage to the torque converter and engine.
Innovation Solution
A controller system that measures the output speed of the rotational power source and torque converter, generating feedback parameters such as speed ratios, derivatives, or integrals, and adjusts the locomotive system's speed to maintain these parameters within an acceptable range, ensuring constant power delivery to the excavating element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the crawler speed is increased to improve machine mobility, then the locomotive element moves faster, but the excavating element speed decreases and pull force increases causing stall and overheating
Solution Approach 1:
The control system continuously monitors the speed of the excavating element and compares it to a reference speed. When the speed deviation exceeds a threshold, the system automatically adjusts the crawler drive parameters to restore the excavating element speed, preventing stall and overheating while maintaining mobility
Solution Approach 2:
The system dynamically adjusts the crawler speed based on real-time operating conditions. The control system modifies locomotive element speed according to the load on the excavating element, creating a dynamic balance that prevents both stall and excessive speed
2Speed
If the crawler pull force is increased to move the machine faster, then locomotion speed improves, but the excavating element experiences excessive load causing stall
Solution Approach 1:
The control system monitors the pull force on the excavating element through speed sensors and feedback mechanisms. When excessive force is detected (indicated by speed reduction or stall), the system automatically reduces crawler pull force to maintain safe operating levels
Solution Approach 2:
The system changes the operational parameters of the crawler drive (speed, torque, power) based on the detected load conditions on the excavating element, dynamically adjusting force transmission to prevent stall while maintaining productivity
3Productivity
If the excavating element operates at high speed continuously, then productivity increases, but the torque converter and engine overheat due to prolonged high load
Solution Approach 1:
The control system implements periodic monitoring and adjustment cycles, temporarily reducing excavating element speed when thermal thresholds are approached, allowing the torque converter and engine to cool while maintaining overall productivity
Solution Approach 2:
The system uses feedback from temperature sensors and operational parameters to detect approaching thermal limits, automatically adjusting excavating element speed to prevent overheating while minimizing impact on productivity
Data Source
AI summary
A controller for crawlers of a trencher receives an indication of the speed of an engine and the speed of an output of a torque converter coupling the engine to an excavating element for digging a trench. Based on the ratio of the speed of the engine and the speed of the output of the torque converter, the controller overrides operator input on the crawlers and stops or slows the trencher when the ratio exceeds a predetermined ranged.