Hydraulic Work Jaw Break Detection from Pump Cycle Pressure Curves
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Solution Overview
Problem
Existing hydraulically actuated work tools, such as crimping tools, face challenges in accurately detecting a break in the work jaw, as they rely on pressure monitoring which can be influenced by the tool's stiffness and the part being crimped, leading to incomplete or improper crimping processes.
Innovation Solution
A method that uses a high-resolution pressure increase curve generated by a piston pump to differentiate between the tool's stiffness and the part's stiffness by comparing the pressure-maintaining range with a predefined value, allowing for immediate detection of a break in the work jaw, and providing visual or acoustic indications for the user.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If pressure monitoring is used to detect work jaw break, then detection capability is provided, but detection accuracy deteriorates due to influence from tool stiffness and part stiffness
Solution Approach 1:
The pressure increase curve is segmented into multiple pump cycles, each containing a pump path and return path. The method analyzes the pressure-maintaining range within each segment to detect breaks, transforming a continuous monitoring problem into discrete cycle-based analysis that eliminates interference from tool and part stiffness
Solution Approach 2:
The system pre-defines pressure-maintaining range values and comparison criteria before operation. By establishing reference pressure intervals and maintaining ranges in advance, the system enables immediate break detection without needing to adapt during operation, resolving the accuracy issue caused by varying stiffness conditions
2Measurement precision
If high-resolution pressure increase curve is generated, then break detection precision is improved, but system complexity increases
Solution Approach 1:
The piston pump's inherent periodic operation (pump path and return path) automatically generates the high-resolution pressure increase curve without requiring additional sensors or complex monitoring equipment. The system utilizes the existing pump cycles to create the detailed pressure profile needed for accurate break detection
Solution Approach 2:
The method changes the analysis parameter from absolute pressure values to pressure-maintaining range characteristics within each pump cycle. By focusing on the pressure interval and maintaining range rather than peak pressure, the system achieves high detection precision using simple comparison logic against predefined values
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 approach enables precise detection of a break in the work jaw, preventing further operation and ensuring proper crimping by distinguishing the tool's stiffness from the part's, thus enhancing the reliability of the work process.
Implementation Method 1
the hydraulic pressure is further applied with the aid of a piston pump, with a pump piston that travels through a pump path and a return path in each pump cycle
Implementation Method 2
while the hydraulic pressure is recorded over time given a change from the pump path to the return path
Data Source
AI summary
A method for operating a hydraulically actuated work tool having a work jaw is provided. Once an increase in force applied as a result of a hydraulic pressure has been reached, the work process does not require any further force or a maximum permissible hydraulic pressure has been reached. The hydraulic pressure is applied by a pump piston that travels through a pump path and a return path in each pump cycle. The hydraulic pressure is recorded over a time for a change from a pressure increase range to a pressure-maintaining range corresponding substantially to a specific pressure value from the pump path into the return path. At the end of a pump cycle, if the reached pressure-maintaining range exceeds a predefined pressure-maintaining range, an indication is concluded that the tool needs to be checked for a break in the work jaw.