Truck measurement of milling machine

Abstract

A milling machine may include a frame supported by a traction device, a milling roller for milling surfaces and supported on the frame, and a conveyor for receiving milled material from the milling roller and conveying the milled material upward to a release point. The milling machine may include truck sensors configured to monitor the milling machine's loading onto a truck, and a controller communicating with the truck sensors to coordinate with them and identify when the truck is full.

Description

Technical Field

[0001] This invention generally relates to the collection and use of data from milling machines. More specifically, this invention relates to a calculation and loading system for milling machines. More specifically, this invention relates to a truck calculation system and a truck sensing and loading system for milling machines. Background Technology

[0002] Roads are constructed to facilitate vehicle traffic. Depending on usage density, foundation conditions, temperature variations, humidity levels, and / or physical aging, road surfaces may eventually become deformed; cracks may form, allowing water to enter and causing freeze-thaw damage; and other forms of wear and tear may occur. Roads may become unable to support wheel loads or may become unsuitable for vehicle traffic. To repair roads so that they can continue to be used by vehicles, the used road material can be removed to prepare for surface resurfacing.

[0003] Milling machines, such as cold planers, rippers, and reclaimers, can be used to break up and remove layers of asphalt pavement. Reclaimers can tear the road surface, mix it with or without additives, and return it as a base layer for additional paving. Conversely, cold planers or rippers can cut and remove the road surface. For example, a cold planer typically consists of a frame propelled by a tracked or wheeled drive unit. The frame supports an engine, operator station, milling drum, and conveyor. The milling drum, equipped with cutting tools, rotates through a suitable interface with the engine to mill the road surface. The milled road material is deposited by the milling drum onto a conveyor, which transfers the milled material to trailer trucks for removal from the site. When the trailer trucks are full, they are replaced by empty ones. The full trucks transport the milled material to different locations, such as asphalt plants, for reuse as aggregate in new asphalt or for other recycling purposes. This transport process is repeated until the milling process is complete.

[0004] For various purposes, such as billing, work estimation, and ongoing paving operations, knowing the number and size of trucks being filled by the milling machine can be useful for milling operators. Current systems may rely on counts that occur at the asphalt plant when trucks return with milled material. In many cases, the asphalt plant may be operated by different companies or contractors involved in the surface resurfacing project.

[0005] Beyond the number of trucks, information about truck capacity and fill volume can be useful for the purpose of effectively utilizing truck resources without overloading them. In many cases, current filling operations rely on visual inspections, estimates of fill levels, or other user judgment to determine when and / or whether a truck is full. These judgments can be inaccurate and potentially problematic. For example, if a truck is overloaded, the trucking company may incur fines for exceeding road axle load limits. Furthermore, if a truck is underfilled, project costs may increase due to truck inefficiency.

[0006] Chinese Patent Application No. 201910940523 relates to a truck loading counting method and system. This application discusses obtaining loading information from a loading positioning device installed on a vehicle; determining whether the vehicle is fully loaded based on the loading information; and if fully loaded, initiating a task to obtain the geographical location information of the loading positioning device. Summary of the Invention

[0007] In one or more embodiments, a milling machine may include a frame supported by a traction device, a milling roller for milling a surface and supported on the frame, and a conveyor for receiving milled material from the milling roller and conveying the milled material upward to a release point. The milling machine may also include a truck sensor configured to identify trucks and a controller communicating with the truck sensor to coordinate with the truck sensor and maintain and store truck counts.

[0008] In one or more embodiments, a counting method may include using a controller on a milling machine coordinated with truck sensors to monitor the area around the truck's milling machine. The method may also include performing truck counting to generate and store truck counts.

[0009] In one or more embodiments, a milling machine may include a frame supported by a traction device, a milling roller for milling a surface and supported on the frame, and a conveyor for receiving milled material from the milling roller and conveying the milled material upward to a release point. The milling machine may also include a loading sensor configured to monitor the milling machine's loading onto a truck; and a controller that communicates with the loading sensor to coordinate with it and identify when the truck is full.

[0010] In one or more embodiments, a method for load monitoring may include obtaining volume, milling surfaces to produce milled material, and conveying the milled material into a truck bed. The method may also include scanning the truck bed to obtain the material volume and comparing the material volume with a volume.

[0011] In one or more embodiments, a load monitoring method may include monitoring readings from an axle scale on a truck, milling surfaces to produce milled material, and conveying the milled material into a truck bed. The method may also include stopping milling and conveying when the readings reach a selected axle load.

[0012] In one or more embodiments, a milling machine may include a frame supported by a traction device, a milling roller for milling surfaces and supported on the frame, and a conveyor for receiving milled material from the milling roller and conveying the milled material upward to a release point. The milling machine may also include sensors configured to scan truck beds and a controller communicating with and coordinating with the sensors. The controller is further configured to store truck counts and identify when the truck beds are full. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of a road milling project according to one or more embodiments.

[0014] Figure 2 It is a schematic diagram of a road milling site and surrounding area according to one or more embodiments.

[0015] Figure 3 This is a side view of a milling machine for loading trucks according to one or more embodiments.

[0016] Figure 4 It is a rear perspective view of an empty dump truck according to one or more embodiments.

[0017] Figure 5 It is a rear perspective view of a partially filled dump truck according to one or more embodiments.

[0018] Figure 6 It is a rear perspective view of a fully loaded dump truck according to one or more embodiments.

[0019] Figure 7 This is a method diagram illustrating an accounting method according to one or more embodiments.

[0020] Figure 8 This is a method diagram illustrating a load monitoring method according to one or more embodiments.

[0021] Figure 9 This is a method diagram illustrating a load monitoring method according to one or more embodiments. Detailed Implementation

[0022] Figure 1This is a schematic diagram of a road milling project. As shown, for example, a milling project may include a milling machine 100 such as a cold planer. The cold planer may be located at the milling site and can be operated to remove one or more layers of road material from the road surface. The cold planer may utilize a rotating device or milling drum that produces granular material from a broken surface to remove the material.

[0023] like Figure 2 As shown, the cold planer may include a frame 102 supported by one or more traction devices 104, a milling drum 106 rotatably supported under the belly of the frame 102, and an engine 108 mounted to the frame 102 and configured to drive the milling drum 106 and the traction devices 104. The traction devices 104 may include wheels or tracks connected to actuators adapted to controllably raise and lower the frame 102 relative to the ground surface. Raising and lowering the frame 102 may also be used to change the milling depth of the milling drum 106 into the surface 50. In some embodiments, the same or different actuators may also be used, if desired, to steer the cold planer 100 and / or adjust the travel speed of the traction devices 104 (e.g., accelerate or brake the traction devices 104). A conveyor system 110 may be pivotally connected to the frame 102 at its front end and configured to transport material from the milling drum 106 into a transport vehicle or truck 52.

[0024] Frame 102 may also support operator station 112. Operator station 112 may accommodate any number of interface devices 114 for controlling cold planer 100. In the disclosed examples, interface devices 114 may in particular include displays, warning devices, and input devices. In other embodiments, operator station 112 may be a non-vehicle-mounted cold planer 100. For example, operator station 112 may be embodied as a remote controller, such as a handheld controller, which an operator can use to control cold planer 100 from anywhere on or away from the construction site. Operator station 112 may alternatively be embodied as software programs and a user interface for a computer and may include a combination of hardware and software. In other embodiments, cold planer 100 may be autonomous and may not include operator station 112.

[0025] The display can be configured to show the position of the cold planer 100 (e.g., milling drum 106) relative to a site feature (e.g., milled and / or unmilled portions of surface 50) and to display data and / or other information to the operator. Warning devices can be configured to audibly and / or visually warn the operator of the cold planer 100 regarding the proximity of the milling drum 106 to the site feature, and / or when certain data segments exceed associated thresholds, such as when a loading truck is full. Input devices can be configured to receive data and / or control commands from the operator of the cold planer 100. Other interface devices (e.g., control devices) are also possible, and one or more of the aforementioned interface devices can be combined into a single interface device if needed.

[0026] The input device may be an analog input device that receives control commands, such as via one or more buttons, switches, dials, joysticks, etc. The input device may also, or alternatively, include digital components, such as one or more soft keys, a touchscreen, and / or a visual display. The input device may be configured to generate one or more signals based on input received from the operator, indicating various parameters associated with the cold planer 100 and / or its surrounding environment.

[0027] The conveyor system 110 may include a first conveyor adjacent to the milling roller 106, configured to transfer milling material to a second conveyor. The conveyors may be pivotally attached to the frame 102, thereby allowing adjustment of the height at which the milling material leaves the conveyor. In other words, the vertical pivot orientation of the conveyor can be adjusted to raise and lower the conveyor. The conveyors may also be pivotally attached to the frame 102, thereby allowing adjustment of the lateral position of the milling material leaving the conveyor. In other words, the horizontal pivot orientation of the conveyor can be adjusted to move the conveyor from one side to the other.

[0028] The conveyor may include a belt supported on a plurality of roller assemblies and driven by a motor. The motor may, for example, be a hydraulic motor powered by a hydraulic system (not shown). In other embodiments, the motor may be an electric motor or other types of motor. The motor may be powered by an engine or another power source.

[0029] The conveyor can receive milled material from the milling drum and transport it upwards from the processing area to a release point, where it can be released into, for example, a truck bed. Figure 1As shown, one or more trucks 52 can be used to haul material away from the road milling project. In one or more embodiments, trucks 52 can deliver material to an asphalt plant 54, where the asphalt plant 54 can reuse the material as aggregate in its asphalt manufacturing process. In other embodiments, trucks 52 can deliver material to a landfill or recycling facility. In some embodiments, multiple material delivery locations may be used. In one or more embodiments, trucks 52 can return to the road milling site to receive and haul away additional material. The cycle of trucks 52 can continue while the milling machine 100 is in operation.

[0030] Figure 3 A schematic diagram of road milling site 116 is shown, such as... Figure 1 The construction site shown in the diagram is part of the entire project. As shown, the milling machine 100 can be the relatively central object on the road milling site 116. The truck 52 can enter the site 116, wait for a turn as needed to receive the milled material, approach the milling machine 100, receive the material, and then leave the milling machine and the road milling site 116.

[0031] In one or more embodiments, the milling machine 100 may be configured to perform an encounter calculation with the truck 52 and may be further configured to help properly load the truck to a full load level. The calculation may include counting the number of trucks or truck counts, and may also include collecting additional information about the trucks. Properly loading the trucks may include establishing the truck bed volume, monitoring the flow of material into the truck bed, and identifying when the truck bed is full. The milling machine may include an accounting and loading system for performing the above operations. The accounting and loading system may include a truck sensor 118, a loading sensor 120, and a controller 122 communicating with the truck sensor 118 and the loading sensor 120. It should be understood that while an accounting and loading system has been discussed, the truck counting and loading process may be performed by a separate dedicated system rather than a combined system.

[0032] like Figure 2 As shown, truck sensor 118 can be positioned on or near milling machine 100 and can be configured to identify the presence of trucks and / or interaction with trucks. In other words, truck sensor 118 is capable of distinguishing dump trucks from pickup trucks or from other equipment, vehicles, debris, or workers that may be present at milling site 100. Accordingly, truck sensor 118 can provide reliable data on the number of trucks loaded by milling machine.

[0033] The truck sensor 118 can be located at one or more locations on the project site. In one or more embodiments, such as Figure 2As shown, the truck sensor 118 can be positioned at or near the top of the conveyor 110, providing the sensor with an elevated position on the project site and a proper view close to the truck. Furthermore, this position provides the truck sensor 118 with a line of sight over the truck bed, allowing the truck sensor to directly assess the dimensions of the truck bed. Additionally or alternatively, the truck sensor 118 can be located away from the milling machine 100, providing the truck sensor with a wider line of sight over the project site and equipment interactions. In one or more embodiments, the truck sensor can be positioned on a tripod or a movable platform so that the truck sensor can move with the milling machine as it travels along the road. In one or more embodiments, the truck sensor can be mounted on a drone, providing a high level of flexibility in the truck sensor's location. Other mounting locations and / or systems may also be provided.

[0034] In one or more embodiments, truck sensor 118 may be a feature-finding device. In other words, the truck sensor may work in conjunction with identification features 124 on truck 52 or other systems to identify and / or recognize truck 52. For example, truck 52 may include QR codes on one or more selected surfaces of truck 52, such as painted QR code designs, decals, magnets, or otherwise applied QR codes. Alternatively or additionally, identification feature 124 may include RFID tags or devices. Alternatively or additionally, identification feature 124 may include Bluetooth transponders and / or Wi-Fi transponders. In these cases, truck sensor 118 may include appropriate sensors such as QR code scanners, RFID scanners, Bluetooth transmitters / receivers, and / or Wi-Fi transmitters / receivers. Figure 3 As shown, identification feature 124 may include a GPS transponder, and truck sensor 118 may also include a GPS transponder. Geofencing 126 may be placed around milling machine 100, and trucks crossing the geofence can be counted and identified.

[0035] Depending on the truck fleet used to transport milled materials, one or more of various types of identification features 124 may be present on one or more trucks 52 in the fleet. Accordingly, multiple types of truck sensors 118 may be present on the milling machine 100 to provide flexibility in working with multiple trucks 52 having multiple identification features 124.

[0036] In one or more embodiments, truck sensor 118 may include a one-sided device. In other words, as an alternative to or supplement to a feature-finding device, truck sensor 118 may be adapted to identify truck 52 or multiple trucks 52 without requiring any specific identifying features on the truck 52. The one-sided device may include a camera, 3D or 2D scanner, radar, lidar, or other device configured to identify the presence of truck 52 and / or track the movement of truck 52 without requiring any specific features or devices on the truck itself. The one-sided device may be supported by computer software adapted to analyze data received from the device (such as image data or point cloud data) and assess the presence of truck 52. In one or more embodiments, the computer software may include a series of metrics that generally define the size and shape of the truck (such as a dump truck), for example, allowing the system to identify the presence of the truck. In one or more embodiments, more detailed metrics may be used to identify the specific type of truck present and / or assess the size of the truck.

[0037] In any of the above-described scenarios, truck sensor 118 can continuously or periodically scan the project site of truck 52 and / or the area near milling machine 100. Truck sensor 118 can communicate with the controller via wired or wireless means, and can transmit truck information to the controller for processing. It should be understood that, in addition to identifying the presence of individual trucks or their interaction with the milling machine, identification features on the trucks can allow the capture of information about each truck. In other words, for example, QR codes, RFID devices, Bluetooth transponders, Wi-Fi transponders, or GPS transponders can contain information about the truck's manufacture and model, truck bed dimensions, load capacity, axle count, axle load, target load, or other information about the truck. Truck sensor 118 can also transmit this information to the controller.

[0038] Load sensor 120 can be configured to monitor the loading of truck 52 by the milling machine and can allow controller 122 to identify the loading status of the truck (e.g., empty, specific full level, full, edge-to-edge weighted, etc.). Depending on the nature of truck sensor 118, load sensor 120 can be an integral part of truck sensor 118. In other words, where truck sensor 118 has the ability to allow counting trucks and monitoring truck loading, truck sensor 118 and load sensor 120 can be a single sensor that allows both functions to be performed.

[0039] In one or more embodiments, the loading sensor 120 may include a 3D scanner or a smart camera. The loading sensor 120 may be positioned at or near the top of the conveyor 110 on the milling machine 100 to provide a top-down view of the truck bed 56 as the truck returns below the conveyor 110. The loading sensor 120 may scan the truck bed 56 to establish available volume and may continuously or periodically monitor the filling of the truck bed 56. In other words, as Figure 4-6 As shown, the loading sensor 120 can capture images of the truck bed 56 and transmit these images to a controller to allow determination of the volume of material in the truck bed. For example, this information can be used to automatically begin loading (e.g., when the truck is present and empty), monitor the loading process, and automatically stop loading when the truck is full. Using density information about the milled road material, the controller can further determine the weight of the material in the truck bed. With truck capacity information available via the truck sensor information, the controller can therefore determine when a particular truck is fully loaded and automatically stop loading. It should be understood that the loading sensor 120 can also be positioned in other locations, for example, on a drone that is wired or wirelessly connected to the milling machine 100.

[0040] In other embodiments, truck 52 may include a loading sensor 120. In other words, for example, the truck may include a 3D scanner or smart camera mounted on the roof of the truck cab. The scanner or camera may face rearward and may wirelessly communicate with the controller 122 on the milling machine 100. In other embodiments, the loading sensor 120 may be a sensor or system communicating with an axle scale on truck 52. In other words, if the loaded truck is equipped with an axle scale, the loading sensor 120 may be Bluetooth, Wi-Fi, or other wireless communication with the axle scale, and may send this information to the controller 122. In other embodiments, the axle scale may be the loading sensor 120, and the scale may wirelessly communicate with the controller 122. Therefore, in any of these cases, the controller 122 may load the truck until the axle scale reaches its maximum loading limit, and then the controller 122 may automatically stop loading the truck 52.

[0041] Controller 122 may work with truck sensor 118 and / or load sensor 120 to perform accounting operations and monitor and / or control truck loading. In one or more embodiments, controller 122 may include computer-implemented instructions stored in the memory of a computing device. When executed, the computer-implemented instructions may perform one or more methods, such as accounting methods and / or load monitoring methods. In one or more embodiments, the computing device may be a dedicated computing device, or it may be a computing device typically present on a milling machine for controlling and operating the milling machine.

[0042] Industrial applicability

[0043] In operation and use, the accounting and loading system may perform one or more methods. In one or more embodiments, the system may perform an accounting method. (200) The method may include a controller that monitors the area around the milling machine for the presence of a truck. (202) This monitoring may include coordinating with truck sensors to identify the presence of a truck. In one or more embodiments, identifying the presence of a truck may include using the controller to analyze image data or point cloud data generated by the truck sensors to determine the presence of the truck. In one or more other embodiments, identifying the presence of a truck may include identifying identification features on the truck, such as a QR code, RFID, Bluetooth transponder, Wi-Fi transponder, or GPS transponder. In a further embodiment, identifying the presence of a truck may include receiving information about a truck crossing a geofence. In a further embodiment, identifying the presence of a truck may include scanning the truck box volume. In other words, when a 3D scanner or smart camera is provided as a loading sensor, scanning the truck box may indicate the presence of a truck and its interaction with the milling machine. The method may include, for example, performing an accounting of trucks interacting with the milling machine by maintaining a point count or truck count. (204) Maintaining points or truck counts may include storing the number of trucks interacting with the milling machine, adding that number whenever an additional truck is identified, and storing the newly added number. (206) The method can be executed within a time frame that can run concurrently. For example, the method can be performed within a day, during operating hours at a specific site, during a work shift, during the lifespan of the milling machine, and / or during a specific time period selectable by the operator. The method may also include sending points to a back-end system for estimation, bidding, and / or billing for future projects.

[0044] The system can also perform a method for load monitoring. (300) This method may include a controller obtaining the truck box volume. (302) This obtaining may include coordinating with a load monitor and scanning the truck box. For example, a 3D scanner or a smart camera may be used to perform the scanning. In one or more embodiments, the truck box volume may be obtained from a QR code, RFID, or other data containing features on the truck. In one or more embodiments, for example, the load monitor may determine the number of axles on the truck, and the controller may calculate a load estimate based on known permissible axle loads. The load estimate may be used to calculate a volume estimate based on the density of the milled material. The method may include storing the truck box volume or volume estimate, displaying the truck box volume or volume estimate to a milling machine operator, and / or sending the truck box volume or volume estimate to the truck or a central station.

[0045] The method may also include milling the road surface or other surfaces to produce milled material (304) and conveying the milled material into the truck bed (306). The method may also include continuously or periodically rescanning the truck bed using a loading monitor to obtain the material volume or level within the truck bed (308). The method may also include adjusting the position of the conveyor based on images or data from the loading monitor to load the truck bed more evenly. The controller may calculate the material volume and compare it to the truck bed volume or a volume estimate (310), and / or the controller may display the material volume so that the operator can compare it to the truck bed volume or a volume estimate. The method may also include automatically initiating the milling and conveying operation when a truck is present and empty (or not full, such as when a partially full truck arrives). The method may also include automatically stopping the milling and conveying operation when the material volume is equal to the truck bed volume or a selected percentage of the truck bed volume. Alternatively or additionally, the method may include triggering an alarm when the material volume approaches the truck bed volume and the operator can stop the milling and conveying operation.

[0046] In one or more embodiments, the method may further include converting material volume into material weight based on the known density of the milled material. In one or more embodiments, the material weight may be compared to a known weight or load limit of the truck. In other embodiments, the material weight may be compared to multiple axle load limits or other types of load limits. The method may further include storing the volume and / or weight loaded onto the truck and / or storing the amount of time spent loading the truck. The method may further include accumulating the total volume and / or weight of material loaded onto multiple trucks over an entire work shift, day, week, project, or other time period. The method may further include sending individual truck volumes / weights, total volumes / weights, and / or truck loading times to a central station for estimation, bidding, and / or billing for future projects.

[0047] In one or more embodiments, the method for load monitoring (400) may include continuously or periodically monitoring readings from axle scales on a truck (402). The method may include milling a road surface or other surface (404) and conveying the milled material into the truck (406). The method may also include automatically stopping the milling and conveying operation when the reading from the axle scale reaches a selected axle load (408). The method may also include, for example, calculating the total weight of the milled material loaded onto the truck based on the number of axles and axle geometry. The method may also include calculating the volume of the milled material loaded onto the truck based on the density of the milled material. The method may also include accumulating the total volume and / or weight of material loaded onto multiple trucks over an entire work shift, day, week, project, or other time period. The method may also include sending individual truck volumes / weights and / or total volumes / weights to a central station for estimation, bidding, and / or billing for future projects.

[0048] The specific embodiments described above are illustrative and not restrictive. Therefore, the scope of the invention should be determined by referring to the appended claims and the full scope of their authorized equivalents.

Claims

1. A milling machine, comprising: The frame is supported by traction equipment; Milling roller, which is used to mill surfaces and is supported on the frame; A conveyor for receiving milled material from the milling drum and conveying the milled material upward to a release point; Sensors, including scanners, are configured to monitor the milling machine's loading onto the truck; as well as The controller, which communicates with the scanner and is configured to: Control the scanner to scan the truck's cargo box; The empty, usable volume of the box is calculated based on the geometry determined by the scan; The scanner is controlled to periodically scan the truck's bin to monitor the amount of milled material in the bin; Periodically or continuously compare the available volume of the empty space with the amount of milled material to determine when the box is full; The amount of milled material stored is related to the box being full; The total amount of milled material loaded onto multiple trucks within a selected time period; The sensor is configured to provide data on the number of trucks loaded by the milling machine, and the controller is configured to communicate with the sensor to store the truck count.

2. The milling machine according to claim 1, wherein the sensor includes a feature finding device.

3. The milling machine according to claim 2, wherein the feature finding device includes a QR code scanner.

4. The milling machine according to claim 2, wherein the feature finding device includes an RFID scanner.

5. The milling machine of claim 2, wherein the controller is further configured to obtain the truck box volume from features captured by the feature finding device.

6. The milling machine of claim 5, wherein the controller is configured to manage the loading of the truck based on the truck box volume.

7. The milling machine of claim 2, wherein the controller is further configured to determine the number of axles on the truck from features captured by the feature-finding device.

8. The milling machine of claim 7, wherein the controller is further configured to calculate a load estimate based on known permissible shaft loads.

9. The milling machine of claim 1, wherein the controller is further configured to send the total amount of milled material to a background system.

10. The milling machine of claim 1, wherein the controller is further configured to transmit the count of a plurality of trucks to a background.

11. The milling machine according to claim 1, wherein the selected time period is a working day.

12. The milling machine according to claim 1, wherein the selected time period is the site operation time.

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