Wood Chipper Feed Control System Using ECU for Load Management
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Solution Overview
Problem
Traditional wood chipper control systems lack an engine-starting safety mechanism, automatic stopping or reversing of the feed mechanism in response to increased load, and efficient fuel management, leading to potential operator hazards and inefficiencies.
Innovation Solution
A control system that uses electric switches and an electronic control unit (ECU) to monitor the position of the feed control bar, preventing engine start unless in neutral, automatically stopping or reversing the feed wheel upon increased load, and implementing a fuel-saving mechanism by reducing engine speed when the feed mechanism is idle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional hydraulic linkages and valves are used to control feed wheels, then the wood chipper can operate with basic feed control, but the system becomes complex with many hydraulic valves and hoses, and the linkages become fragile and subject to wear
Solution Approach 1:
The patent replaces the traditional mechanical-hydraulic control system with an electronic control system. Electric switches detect the position of the feed control bar, and an electronic control unit (ECU) processes this information to control the feed motors and hydraulic pump motor, eliminating the need for complex mechanical linkages and multiple hydraulic valves.
Solution Approach 2:
The electronic control unit serves multiple functions: it controls the direction of feed motors (forward/reverse/neutral), controls the hydraulic pump motor (on/off), and integrates safety interlocks. This single ECU replaces what previously required multiple specialized hydraulic valves and linkages.
2Adaptability or versatility
If automatic reversal and forward rotation of feed wheel is implemented, then the system can respond to load changes, but the system cannot maintain the feed wheel in a stopped state in response to increased load
Solution Approach 1:
The system dynamically adjusts feed wheel operation based on real-time conditions. The ECU continuously monitors engine load and automatically adjusts feed motor operation between forward rotation, reverse rotation, and stopped states, providing three distinct operational modes that adapt to varying load conditions.
3Extent of automation
If dump valves and reversing valves are added to allow ECU control, then automatic feed wheel control is enabled, but the system presents too many hydraulic valves and hoses
Solution Approach 1:
The patent substitutes electronic control components for hydraulic control components. Instead of using multiple hydraulic valves (dump valves, reversing valves) with associated hoses, the system uses electric switches and an ECU that send electrical signals to control the hydraulic pump motor and feed motors, thereby achieving automatic control with fewer physical components.
4Ease of operation
If the feed control bar actuates directional control valve through linkages, then feed direction can be controlled, but the linkages become fragile and hard to adjust
Solution Approach 1:
The patent replaces the mechanical linkage system with an electronic sensing system. Electric switches detect the position of the feed control bar without physical connection, and the ECU processes this information to control feed motor direction, eliminating fragile mechanical linkages entirely.
5Device complexity
If traditional systems require operator intervention to control feed wheels, then the system is simple to implement, but the operator cannot automatically start, stop or reverse feed wheels in response to load changes
Solution Approach 1:
The system performs self-service through automatic control. The ECU monitors engine load conditions and automatically adjusts feed wheel operation (starting, stopping, reversing) without requiring operator intervention, while the operator simply controls feed direction via the feed control bar.
Data Source
AI summary
A wood chipper includes a control system for controlling feed wheel rotation and engine operation to provide safety features and a fuel-saving mechanism. The control system allows the engine to start only when the feed wheel is in neutral; stops and/or reverses rotation of the feed wheel in response to an increased load on the engine; and dethrottles the engine if the feed wheel remains in neutral for a predetermined period of time. A pair of electric switches are activatable by the feed bar whereby an electronic control unit (ECU) can determine the position of the feed bar based on activation or non-activation of the switches and control the feed wheel and engine in light thereof. The ECU controls a pair of directional control valves via respective solenoids to control flow of hydraulic fluid to control rotation of a feed motor which drives the feed wheel.