Working Hydraulics Load Estimation Using Motor Power for Overload Safety
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Solution Overview
Problem
Existing working machines, such as construction equipment, face safety risks due to overload situations that can lead to loss of control or tipping over, necessitating additional sensors for weight measurement which increase costs.
Innovation Solution
A method using an independent motor drive's power consumption to estimate load on working hydraulics, comparing it with a critical threshold to provide warnings or control commands, eliminating the need for additional pressure sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If additional pressure sensors are installed to measure load on working hydraulics, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The system uses the motor drive's own power consumption data to estimate the load on the working hydraulics. The motor drive serves dual purposes: both actuating the hydraulic system and providing the measurement data needed for load estimation, eliminating the need for separate pressure sensors.
Solution Approach 2:
The patent replaces the mechanical/physical pressure sensing system with an electrical measurement approach. Instead of using pressure sensors to directly measure hydraulic load, the system uses electrical power consumption data from the motor drive to indirectly estimate the mechanical load through a load estimation model.
2Reliability
If additional pressure sensors are installed to detect overload conditions, then reliability is improved, but cost increases
Solution Approach 1:
The motor drive system provides both the actuation function and the measurement function for safety monitoring. By using the power consumption data from the motor drive that is already present in the system, the patent achieves safety monitoring without adding separate sensing components.
Solution Approach 2:
The motor drive system is made multi-functional by using its power consumption data for both controlling the hydraulic actuation and for estimating the load to detect overload conditions. This single component serves multiple purposes: actuation, measurement, and safety monitoring.
3Device complexity
If load estimation model uses motor power consumption data, then device complexity is reduced, but measurement precision may worsen
Solution Approach 1:
The load estimation model uses feedback from the motor drive's power consumption data to continuously monitor and estimate the actual load on the working hydraulics. This feedback mechanism allows the system to adapt to varying operating conditions and provide accurate load estimation without additional sensors.
Solution Approach 2:
The patent changes the measurement parameter from direct physical pressure measurement to electrical power consumption measurement. By using electrical parameters (power, current, voltage) from the motor drive, the system achieves load estimation without the need for mechanical pressure sensing components.
Data Source
AI summary
A working machine has working hydraulics comprising a pump. The working machine has an independent motor drive for powering the working hydraulics. a load on the working hydraulics is estimated based on a load estimation model using an actual motor power consumption of the independent motor drive. The estimated load is compared with a critical threshold. If the estimated load is above the critical threshold a warning signal or a control command stopping an actual movement is provided.