System and method for replacing a wear part

Abstract

A system includes a carrier assembly, a replacement tool movably supported by the carrier assembly, and a sensor configured to capture sensor data associated with a wear part removably connected to a rotatable drum. The system also includes a controller configured to receive the sensor data from the sensor and use the sensor data to identify the wear part. In such a system, the carrier assembly is configured to move the replacement tool such that an axis of the replacement tool is substantially co-linear with an axis of the wear part. Additionally, the replacement tool is configured for removing the wear part from the rotating drum while the axis of the replacement tool is substantially co-linear with the axis of the wear part.

Description

Technical Field

[0001] The present invention generally relates to worn parts on a rotatable drum for a milling machine, and more specifically to systems and methods for replacing such worn parts based on sensor data captured by one or more sensors. Background Technology

[0002] To facilitate earthmoving operations (e.g., paving, mining, construction, dredging, etc.), machines are typically equipped with ground engagement tools. For example, tools including, but not limited to, teeth, drill bits, cutting teeth, spikes, guards, and / or lips are usually provided to protect the underlying equipment from undue wear and / or to perform other functions. As a non-limiting example, cold milling machines or other such milling machines typically include a rotating drum equipped with teeth, drill bits, or other replaceable wear parts, configured to contact the ground and break or remove material to the desired depth. During use, these wear parts encounter heavy loads and / or high abrasion conditions. These conditions cause these components to wear, eventually leading to wear or failure. Excessive wear can result in breakage and / or loss of wear parts, which can lead to reduced productivity, increased repair and / or maintenance costs, and other problems. Therefore, it is necessary to monitor component wear and replace worn parts with new parts during shift changes or scheduled maintenance. However, due to the size and complexity of such machines, and the harsh environments in which they are used, replacing worn parts with new parts is difficult and time-consuming.

[0003] The system is designed to help machine operators monitor wear associated with replaceable worn parts. For example, U.S. Patent No. 8,386,196 ('196 Patent) by Wagner et al. describes a system and method for determining part wear using non-contact measurement methods. For example, the '196 Patent describes capturing digital images of various worn parts using a camera. The '196 Patent also describes using the captured images to characterize the amount of wear associated with such worn parts. For example, the '196 Patent describes determining the distance between the worn surface of the imaging portion and the corresponding surfaces shown in the images of the unworn portion, and characterizing the imaging portion based on this distance. In some examples, the system described in the '196 Patent estimates the degree of wear associated with the imaging portion based on these distances.

[0004] While the system described in the '196 patent is configured to assess the degree of wear associated with worn parts, it is not well-suited for identifying one or more worn parts among a plurality of worn parts that require replacement. Furthermore, the system described in the '196 patent does not include a tool configured to remove the worn part from the machine, or one or more additional components configured to align such a tool with the worn part, allowing the tool to be operated to remove the worn part. As a result, the wear of components assessed by the system of the '196 patent may remain unresolved, leading to increased maintenance costs and potential machine downtime.

[0005] The present invention aims to overcome one or more of the above-mentioned defects. Summary of the Invention

[0006] One example of the invention relates to a system including a support assembly, a replacement tool movably supported by the support assembly, and a sensor configured to capture sensor data associated with a plurality of worn parts removably connected to a rotatable roller. The example system also includes a controller configured to receive the sensor data from the sensor and use the sensor data to identify a worn part among the plurality of worn parts that needs to be replaced. Based at least in part on the controller's identification of the worn part, the support assembly is configured to move the replacement tool relative to the worn part such that the replacement tool engages with the worn part. Additionally, based at least in part on the controller's identification of the worn part, the replacement tool is configured to remove the worn part from the roller when the replacement tool engages with the worn part.

[0007] Another example of the invention relates to a method comprising receiving sensor data from sensors associated with a plurality of worn parts removably connected to a rotatable roller using a controller. The method further comprises using the controller and based on the sensor data to identify worn parts that require replacement among the plurality of worn parts. The method also comprises using the controller to move the roller to a replacement orientation in which the worn parts are accessible by a replacement system operatively connected to the controller. Additionally, the method comprises using the controller to control a replacement tool of the replacement system to engage with and remove the worn parts from the roller.

[0008] Another example of the invention relates to a milling machine including a frame, a roller rotatable relative to the frame, a plurality of wear parts removably connected to the roller, and a sensor fixedly connected to the frame such that the plurality of wear parts are within the field of view of the sensor. The milling machine also includes a controller configured to receive sensor data from the sensor, the sensor data including images of the plurality of wear parts. In such an example, the controller is configured to identify wear parts that need to be replaced among the plurality of wear parts based on the sensor data. The controller is also configured to move the roller to a replacement orientation in which the wear parts are accessible by a replacement system operably connected to the controller, the replacement assembly including a carrier assembly movable relative to the frame and a replacement tool movably supported by the carrier assembly. Additionally, the controller is configured to control the replacement tool to engage with the wear parts and remove the wear parts from the roller. Attached Figure Description

[0009] Figure 1 An example of a system configured to identify and / or assist in replacing one or more worn parts according to the present invention is shown.

[0010] Figure 2 An example of the invention is shown with Figure 1 The system is shown, along with associated carrier components and replacement tools.

[0011] Figure 3 A replacement system according to another example of the present invention is shown.

[0012] Figure 4 A replacement system according to yet another example of the invention is shown.

[0013] Figure 5 This is a flowchart illustrating a method for replacing worn parts according to an example of the present invention. Detailed Implementation

[0014] This invention generally relates to systems and methods for replacing worn parts on mobile machinery. While specific worn parts are described herein with respect to ground-jointing machines, earthmoving machines, etc., the systems and methods described herein are applicable to any machine parts that wear down over time due to abrasion, corrosion, impact, friction, or use in paving, mining, construction, agriculture, or other applications. Where possible, the same reference numerals are used throughout the drawings to refer to the same or similar features.

[0015] Figure 1An example system 100 for replacing worn parts according to an implementation of the present invention is shown. Components of system 100 are configured to interact with each other to capture sensor data. In some examples, the sensor data includes images of multiple worn parts removably attached to machine parts, identifying one or more worn parts shown in the images that require replacement, and facilitating the removal and / or replacement of the identified worn parts. Figure 1 In this embodiment, system 100 is shown at least partially located at a paving site, building site, mining site, quarry, excavation site, or other such work site 102. The illustrated system 100 includes at least one milling machine, cold planer, bituminous mill, rotary mixer, bulldozer, mining machine, excavator, or other such machine 104 configured to perform one or more tasks at work site 102. In this example of the invention, one or more of the machines 104 are configured to perform one or more such tasks (e.g., without receiving input from operator 106). Alternatively, one or more machines 104 may be configured to perform one or more such tasks semi-automatically (e.g., at least partially based on input received from operator 106) or under the full manual control of operator 106.

[0016] Machine 104 includes one or more wear-prone parts, the wear of which is caused, for example, by forces acting on these parts during operation of machine 104, and must be replaced over time due to this wear. For the purposes of discussion, example machine 104 is shown as a cold planer or other such milling machine, and example machine 104 includes a roller assembly 108 configured to act on a working surface 110, on which machine 104 is positioned. Such working surfaces 110 include, for example, road surfaces, concrete, asphalt, gravel, soil, sand, overburden, and / or any other material, and example working surfaces 110 include other surfaces at roads, highways, parking lots, and / or construction sites 102, which will be rolled, ground, removed, and / or otherwise acted upon by machine 104.

[0017] like Figure 1 As shown in the enlarged view 112, the roller assembly 108 includes a rotatable roller 114 and one or more teeth, drill bits, tools, or other such wear parts 116 removably connected to the roller 114. For example, Figure 1Enlarged view 112 shows an example of a generally cylindrical roller 114 having a plurality of wear parts 116 disposed at corresponding locations on the outer surface 118 of the roller 114. These wear parts 116 are shown as operable on the underside or working surface engagement side of the machine 104. Therefore, individual wear parts 116 are not readily replaceable in all orientations of the roller 114. Illustrative examples include moving the roller 114, for example, rotating the roller 114 relative to the frame 120 of the machine 114 supporting the roller 114, to an orientation that presents or moves the individual wear parts 116 to a position where the wear parts 116 are accessible for removal and / or replacement (e.g., a "replacement orientation"). In some examples, the machine 104 includes hatches, guards, or doors (not shown) that allow an operator 106 to access a portion of the roller 114 without removing the roller 114 from the machine 104. Rotating the roller 114 to the replacement orientation makes one or more wear parts 116 (including, for example, a single worn wear part 116) accessible for replacement. In such an example, approaching one or more additional wear parts 116 located at other circumferential positions on the outer surface 118 of the roller 114 requires rotating the roller 114 to a different replacement orientation corresponding to such additional wear parts 116. In any of the examples described herein, rotating and / or otherwise moving the roller 114 to the replacement orientation positions one or more wear parts 116 such that the wear parts 116 are accessible by a replacement system operable to remove the wear parts 116 from the roller 114 and / or install one or more new wear parts 116 on the roller 114. Such an example replacement system will be described below.

[0018] In addition to or in place of the wear part 116 shown, machine 104 may include other high-stress components, tools, or wear parts of tracks made of individual track links, blades with edges for moving material, and / or other parts that wear over time as machine 104 performs various tasks at site 102. In other examples, machine 104 may be or may include working tools, such as saws or drills, having one or more parts that wear over time, such as chains, blades, edges, teeth, or drill bits. As used herein, the term “wear part” refers to a component of machine 104 that is subjected to stress, strain, corrosion, and / or other forces during use, which cause these components to wear over time. The systems and methods described herein can determine the wear and replacement needs of such wear parts and can be used to remove and reinstall such wear parts, regardless of the type of machine to which they are associated.

[0019] Continue to refer to Figure 1The roller 114 includes a longitudinal axis 122 that extends substantially centrally through the entire length of the roller 114. The roller 114 also includes a first transverse axis 124 (e.g., a substantially horizontal axis) disposed in a plane (not shown) substantially perpendicular to the longitudinal axis 122. The plane including the first transverse axis 124 may, for example, be substantially parallel to the side or face 126 of the roller 114. The roller 114 also includes a second transverse axis 128 (e.g., a substantially vertical axis) disposed in the aforementioned plane. In such an example, the first transverse axis 124 and the second transverse axis 128 extend substantially parallel to the face 126 of the roller 114 and substantially perpendicular to the longitudinal axis 122. In operation, the roller 114 is controlled to rotate about the longitudinal axis 122 in a clockwise direction 130 or a counterclockwise direction 132 to aid in the removal of road surface, asphalt, or other materials from the work surface 110. In this process, one or more wear parts 116 removably attached to the rotating roller 114 impact and / or otherwise act on the working surface 110 to remove at least a portion of the working surface 112, and the removed portion of the working surface 112 is conveyed from the roller assembly 108 to a towing truck or other machine at the site 102 via one or more conveyors, screw conveyors, or other material handling components of the machine 104. Additionally, as described below, the replacement system of the present invention can be configured to deliver, orient, move, and / or otherwise position the replacement tool relative to one or more wear parts 116 removably attached to the roller 114. In some examples, the replacement system includes one or more components configured to move the replacement tool along an axis 122' substantially parallel to the longitudinal axis 122 of the roller 114, along an axis 124' substantially parallel to the first transverse axis 124, and / or along an axis 128' substantially parallel to the second transverse axis. In any of the examples described herein, such components are also configured to pivot and / or otherwise rotate the replacement tool about axes 122', 124', 128'. For example, these components of replacement system 138 are configured to rotate replacement tool 142 about longitudinal axis 122' in a clockwise direction 130' or a counterclockwise direction 132' to aid in aligning replacement tool 142 with one or more worn parts 116. As described below, in some examples, replacement tool 142 is configured to remove worn parts 116 from roller 114 and / or mount worn parts 116 onto roller 114 when the replacement tool is aligned and / or otherwise positioned as described above.

[0020] Figure 1The illustrated system 100 also includes at least one sensor 134 connected to the machine 104 and positioned at a location where at least a portion of the roller 114 is within the field of view 136 of the sensor 134. In some examples, the sensor 134 includes a stationary sensor fixedly mounted to the frame 120 near the roller assembly 108, such that at least a portion of the roller 114 (e.g., at least a portion of the outer surface 118) and one or more wear parts 116 are positioned within the field of view 136 during operation of the machine 102. In other examples, the sensor 134 is mounted to one or more links, actuators, or other components configured to move the sensor 134 relative to the roller 114. In such examples, movement of the sensor 134 causes corresponding changes in the portion of the roller 114 and one or more wear parts 116 positioned within the field of view 136, and such movement helps the sensor 134 (e.g., enhances the ability of the sensor 134) capture sensor data corresponding to and / or otherwise associated with one or more wear parts 116. In the examples, sensor 134 may be an optical sensor, a two-dimensional digital camera, a three-dimensional digital camera, or a ranging sensor, including but not limited to radar sensors, light detection and ranging (LIDAR) sensors, proximity sensors, etc. As a non-limiting example, sensor 134 may be a time-of-flight sensor configured to determine and / or generate depth associated with each captured pixel. In some examples, sensor 134 may be moved, focused, manipulated, and / or otherwise operated by operator 106 to capture sensor data corresponding to and / or otherwise associated with wear parts 116. For example, sensor data captured by sensor 134 may include video and / or one or more images (e.g., still images) of one or more wear parts 116 removably attached to roller 114. In some examples, sensor 134 includes a high-speed imaging device configured to capture such sensor data (e.g., one or more images, videos, etc.) as roller 114 rotates about longitudinal axis 122. Additionally or alternatively, sensor 134 is configured to capture any sensor data described herein when roller 114 is stationary (e.g., not rotating) relative to frame 120 and / or relative to sensor 134. In another example, sensor 134 includes a handheld or otherwise movable imager or sensor, and in such an example, operator 106 may position sensor 134 relative to roller 114 (e.g., on a tripod set on work surface 110) to capture video and / or images of one or more wear parts 116. In any of the examples described herein, sensor 134 may include a proximity sensor or other positioning device configured to identify position on roller 114, position and / or orientation of one or more wear parts 116, position and / or orientation of replacement tools or other components of system 100, etc.In such an example, the sensor data captured by sensor 134 includes coordinates, point cloud information, and / or other information indicating (e.g., wear part 116) the position and / or orientation of the item relative to sensor 134 and / or relative to one or more fixed / known locations on machine 104. It should be understood that any sensor data described herein may include such positional information and / or any images, videos, or other information described above regarding sensor 134.

[0021] As stated above, and as Figure 1 As shown, in some examples, system 100 includes a replacement system 138, which includes a carrier assembly 140 movable relative to a frame 120 of machine 104 and a replacement tool 142 movably supported by the carrier assembly 140. In any of the examples described herein, the carrier assembly 140 is configured to pivot, rotate, translate, and / or otherwise move the replacement tool 142 relative to roller 114 and / or relative to one or more worn parts 116, such that the replacement tool 142 ( Figure 2The axis of the replacement tool 142 (e.g., the central longitudinal axis) is substantially collinear with the axis 145 (e.g., the central longitudinal axis) of the worn part 116 to be replaced. In some examples, the replacement system 138 and / or the carrier assembly 140 also includes an orienting device 144 configured to pivot, rotate, translate, and / or otherwise move the replacement tool 142 relative to the roller 114 and / or relative to one or more worn parts 116. In such examples, the replacement tool 142 is positioned by rotation, translation, and / or other movement of the replacement tool 142 via the orienting device 144 such that the axis of the replacement tool 142 is substantially collinear with the axis 145 of the worn part 116 to be replaced. Alternatively, as described below, in other examples, the orienting device 144 may be omitted. In any of the examples described herein, the replacement tool 142 is configured to remove the worn part 116 from the roller 114 when the replacement tool 142 engages with the worn part 116. For example, any of the orienting devices 144 of the present invention is configured to move the replacement tool 142 relative to the worn part 116 such that the replacement tool 142 at least partially contacts, engages, receives, clamps, applies force to a portion of the worn part 116, cuts into a portion of the worn part 116, removes a portion of the worn part 116, and / or otherwise engages with a portion of the worn part 116. In these examples, the orienting device 144 moves the replacement tool 142 to a replacement position in which the replacement tool 142 engages with at least a portion of the worn part 116, and the axis of the replacement tool 142 is substantially collinear with the axis 145 of the worn part 116. In other examples, the orienting device 144 moves the replacement tool 142 to a replacement position in which the replacement tool 142 engages with at least a portion of the worn part 116, and the axis of the replacement tool 142 extends at an angle between approximately 0 degrees and approximately 140 degrees relative to the axis 145. For example, in some configurations, the orientation device 144 moves the replacement tool 142 to a replacement position where it engages with at least a portion of the tip, washer, spring clip, and / or other part or component of the worn part 116. In such an example, the orientation device 144 also orients the replacement tool 142 such that the axis of the replacement tool 142 is set at an angle relative to the axis 145 of the worn part 116 at approximately 30 degrees, approximately 45 degrees, approximately 60 degrees, and / or any other desired angle to facilitate engagement between the replacement tool 142 and the worn part 116. In such an example, components of the machine 104, such as one or more motors, actuators, machine controllers, hydraulic pumps, etc., move the roller 114 to the aforementioned replacement orientation, in which the replacement tool 142, the orientation device 144, the carrier assembly 140, and / or the replacement system 138 are generally accessible to one or more worn parts 116 to be removed by the replacement tool 142.

[0022] Reference Figure 1 In some examples, the orientation device 144 includes one or more components configured to engage with the replacement tool 142 and move the replacement tool 142 relative to the frame 120. In these examples, the orientation device 144 includes a housing configured to mate with and / or otherwise connect to the replacement tool 142. The housing of the orientation device 144 may include one or more flanges, clamps, channels, protrusions, fittings, or other components configured to removably connect the housing of the orientation device 144 to a corresponding base, housing, or other component of the replacement tool 142. The orientation device 144 may also include one or more electric motors (e.g., servo motors), pneumatic actuators, hydraulic cylinders, or other actuators. Figure 2 This component is mounted to and / or otherwise supported by the housing of the orientation device 144, and is configured to move the replacement tool 142 relative to the frame 120, roller 114, one or more wear parts 116, etc. For example, in Figure 1 In the example shown, machine 104 includes one or more tracks 146 disposed near roller assembly 108. The one or more tracks 146 are rigidly connected to frame 120, and in some examples, the one or more tracks 146 extend substantially parallel to the longitudinal axis 122 of roller 114. In such an example, the actuator of orientation device 144 is configured to move changing tool 142 along one or more tracks 146 in the direction of arrow 148 and / or in the direction of arrow 150. Figure 1 As shown, the directions of arrow 148 and arrow 150 are substantially parallel to axis 122', and in such an example, axis 122' can be the central longitudinal axis of one or more tracks 146, the central longitudinal axis of orientation device 144, etc. In such an example, axis 122' is substantially parallel to longitudinal axis 122. Therefore, in such an example, the actuator of orientation device 144 is configured to move changing tool 142 along one or more tracks 146 in a direction substantially parallel to longitudinal axis 122.

[0023] As will refer to Figure 2 The orientation device 144 may also include one or more actuators (e.g., one or more additional actuators) configured to rotate the replacement tool 142 relative to one or more worn parts 116 of the roller 114. For example, such actuators are configured to rotate the replacement tool 142 about a longitudinal axis 122′ in a clockwise direction 130′ and / or a counterclockwise direction 132′ to help align the replacement tool 142 with one or more worn parts 116.

[0024] Continue to refer to Figure 1The shafts 124' and 128' shown, the orientation device 144 also includes one or more actuators (e.g., one or more additional actuators) configured to rotate the replacement tool 142 relative to the shaft 124'. For example, such actuators are configured to rotate the replacement tool 142 about the axis 124' in a clockwise direction 152 and / or a counterclockwise direction 154 to help align the replacement tool 142 with one or more worn parts 116. The orientation device 144 may also include one or more electric motors (e.g., servo motors), pneumatic actuators, hydraulic cylinders, or other actuators. Figure 2 These actuators are mounted to and / or otherwise supported by the housing of the orienting device 144, and are configured to move the changing tool 142 in the direction of arrow 156 and / or arrow 158. In these examples, the directions of arrow 156 and arrow 158 are substantially parallel to axis 124', and in these examples, axis 124' is substantially parallel to the aforementioned first transverse axis 124. Thus, in such examples, the actuators of the orienting device 144 are configured to move the changing tool 142 toward and / or away from the roller 114 in a direction substantially parallel to the first transverse axis 124.

[0025] Furthermore, the orientation device 144 may include one or more actuators (e.g., one or more additional actuators) configured to rotate the replacement tool 142 relative to axis 128'. For example, such actuators are configured to rotate the replacement tool 142 about axis 128' in a clockwise direction 160 and / or a counterclockwise direction 162 to aid in aligning the replacement tool 142 with one or more worn parts 116. The orientation device 144 may also include one or more electric motors (e.g., servo motors), pneumatic actuators, hydraulic cylinders, or other actuators. Figure 2 These actuators are mounted to and / or otherwise supported by the housing of the orienting device 144, and are configured to move the changing tool 142 in the direction of arrow 164 and / or arrow 166. In these examples, the directions of arrow 164 and arrow 166 are substantially parallel to axis 128', and in these examples, axis 128' is substantially parallel to the aforementioned second transverse axis 128. Thus, in such examples, the actuators of the orienting device 144 are configured to move the changing tool 142 toward and / or away from roller 114 in a direction substantially parallel to the second transverse axis 124.

[0026] It should be understood that the movement of the replacement tool 142 via the aforementioned orientation device 144 is merely an example, and the components of the replacement system 138 are configured to provide multiple additional degrees of freedom relative to the worn part 116 described herein. Furthermore, in any example described herein, the replacement system 138 may include one or more additional sensors configured to capture video, still images, location information, orientation information, and / or other sensor data. For example, in any example described herein, the carrier assembly may include one or more sensors 168 movable with the replacement tool 142. In such an example, the sensor 168 is mounted on, disposed within, and / or carried by the housing of the orientation device 144. Alternatively, the sensor 168 is mounted on and / or carried by the replacement tool 142. In such an example, the sensor 168 is substantially similar to and / or identical to the sensor 136. For example, the sensor 168 may be an optical sensor, a two-dimensional digital camera, a three-dimensional digital camera, a high-speed imaging device, or a ranging sensor, including but not limited to radar sensors, LiDAR sensors, time-of-flight sensors, etc. Sensor data captured by sensor 136 may include video and / or one or more images of one or more wear parts 116 removably attached to roller 114.

[0027] In any of the examples described herein, video, images, location information, orientation information, and / or other sensor data captured by sensor 134 and / or sensor 168 may be used to assist in the removal of one or more of the worn parts 116. For example, machine 104 includes machine controller 170, and in such an example, at least one of sensor 136, 168 is operatively connected to and / or otherwise communicates with machine controller 170. Such machine controller 170 is configured to receive video, images, location information, orientation information, and / or other sensor data captured by sensor 136 and / or sensor 168. Such machine controller 170 is also configured to use such sensor data to identify one or more worn parts 116 removably connected to roller 114 that need to be replaced. In any of the examples described herein, roller 114, replacement system 138, carrier assembly 140, replacement tool 142, orientation device 144, and / or other components of system 100 are operatively connected to machine controller 170 such that machine controller 170 can control one or more of its functions. For example, machine controller 170 receives sensor data captured by sensor 168 and inputs such sensor data (e.g., video, one or more images, etc.) into an image recognition engine, algorithm, model, or component. These components identify one or more worn parts 116 that need to be replaced based on the received sensor data. Machine controller 170 uses outputs from these components to control the movement of replacement tool 142 via orientation device 144. Specifically, machine controller 170 uses sensor data received from sensor 168 and / or outputs received from the image recognition engine or the other aforementioned components to control the operation of orientation device 144. This operation includes moving replacement tool 142 to one or more replacement positions described herein. In an example replacement position, replacement tool 142 is configured such that the axis of replacement tool 142 is substantially collinear with axis 145, and one or more arms, cups, end effectors, or other components of replacement tool 142 engage with a specific identified worn part 116. In another example replacement location, the replacement tool 142 is configured such that components of the replacement tool 142 mate with a specific identified worn part 116, and the axis of the replacement tool 142 extends relative to axis 145 at an angle between approximately zero degrees and approximately 140 degrees. The machine controller 170 also uses sensor data and / or other information from sensor 168 to confirm that the replacement tool 142 is properly mated with and / or otherwise positioned relative to the roller 114 and / or the worn part 116, making the replacement tool 142 controllable to remove the worn part 116 from the roller 114.In such an example, sensor data received from sensor 168 enables machine controller 170 to control the movement and operation of orientation device 144 and / or replacement tool 142 when removing worn part 116 from roller 114 and / or when installing worn part 116 onto roller 114.

[0028] exist Figure 1 In the example shown, machine controller 170 may include a single controller or may include more than one controller, and as used herein, the term "controller" in its broadest sense means including one or more controllers, electronic control modules, processors, and / or microprocessors associated with a milling machine, haul truck, compactor, excavator, paver, mining machine, construction machine, or other such machine 104, and cooperating to control various functions and operations of components of machine 104 and / or the replacement system described herein. For example, machine controller 170 is an electronic controller that operates logically to perform operations, execute control algorithms, store and retrieve data, and other desired operations. Machine controller 170 may include or access memory, auxiliary storage devices, processors, and any other components for running applications. Memory and auxiliary storage devices are typically in the form of read-only memory (ROM) or random access memory (RAM) or integrated circuits accessible by controller 170. Various other circuits may be associated with machine controller 170, such as power supply circuits, signal conditioning circuits, driver circuits, and other types of circuits. The functionality of machine controller 170 may be implemented in hardware and / or software without regard to functionality. In some examples, machine controller 170 relies on one or more data maps, lookup tables, algorithms, neural networks, machine learning modules, or other components stored in the memory of machine controller 170. These components typically include collections of data in the form of tables, graphs, and / or equations to maximize the performance and efficiency of machine 104 and its operation.

[0029] In some examples, machine controller 170 includes control system 172 operable to receive sensor data from sensors 136, 168 and control the operation of replacement system 138, carrier assembly 140, replacement tool 142, and / or orientation device 144 based at least in part on this sensor data. For example, control system 172 includes data processor 174 configured to receive such sensor data and determine whether worn part 116 needs replacement. Examples consider evaluating sensor data received from at least one of sensors 136, 168 against a wear model, such as point cloud data, images, or multiple images of worn part 116. Examples consider wear models based at least in part on custom mathematical models of wear, predicted wear, acceptable wear, wear patterns, or combinations thereof. In some examples, wear models are based at least in part on one or more machine learning algorithms and / or models. For example, a wear model executed and / or used by data processor 174 can identify one or more worn parts 116 that need replacement. The data processor 174 can also provide an indication that one or more worn parts 116 need to be replaced, at least in part, based on sensor data received from at least one of the sensors 136, 168. In some examples, the data processor 174 uses a wear model to generate an estimated time (e.g., wear duration) until one or more worn parts 116 removably connected to the roller 114 will need to be replaced.

[0030] Additionally, some components of the control system 172 are configured to assist in controlling the operation of various components of the replacement system described herein. For example, Figure 1The illustrated control system 172 also includes a carrier assembly controller 176 and a replacement tool controller 178. The carrier assembly controller 176 is configured to control the operation of the carrier assembly 140 when removing one or more wear parts 116 and / or when mounting one or more wear parts 116 onto the roller 116. For example, the carrier assembly controller 176 is configured to control the movement of the carrier assembly 140 and / or the orientation device 144 relative to the wear parts 116. In some examples, the carrier assembly controller 176 receives sensor data from at least one of sensors 134, 168 and uses image recognition programs or other components to identify one or more of the wear parts 116. Using these components, the carrier assembly controller 176 also identifies the central axis 145 of the wear parts 116 and controls various actuators of the carrier assembly 140 and / or the orientation device 144 to position the replacement tool 142 in one or more of the aforementioned replacement positions. For example, in some applications, and depending on various configurations of the replacement tool 142, the carrier assembly controller 176 controls the actuators of the carrier assembly 140 and / or the orientation device 144 to move the replacement tool 142 to a replacement position where the axis (e.g., the central axis) of the replacement tool 142 is substantially collinear with the axis 145 of the specific worn part 116 to be replaced. To achieve such an example replacement position, the replacement tool controller 178 also controls the replacement tool 142 to contact, engage, and / or otherwise cooperate with components of the specific worn part 116 and / or the roller 114, which removably connect the worn part 116 to the roller 114.

[0031] The tool changer controller 178 operates in conjunction with the data processor 174 and / or the carrier component controller 176 to control the operation of the tool changer 142. This control causes the tool changer 142 to remove the worn part 116 mating with it from the roller 114, while the tool changer 142 is positioned in one or more of the aforementioned replacement positions (e.g., the axis of the tool changer 142 is substantially collinear with the axis 145 of the specific worn part 116). For example, see reference... Figure 2As described, in some examples, the replacement tool 142 includes a cup configured to engage at least a portion of the worn part 116 (e.g., the tip of the worn part 116). In such examples, the replacement tool 142 may also include one or more arms configured to engage a washer of the worn part 116, and one or more additional arms configured to engage a base block disposed on the outer surface 118 of the roller 114. In such examples, the replacement tool controller 178 controls the relative movement of such arms to typically remove the worn part 116 from the base block and / or from the roller 114. In these examples, the replacement tool controller 178 controls the activation and / or actuation of one or more electric motors, servo motors, hydraulic actuators, pneumatic actuators, and / or other actuators of the replacement tool 142 to remove the worn part 116 from the roller 114 via the replacement tool 142. It should be understood that the replacement tool controller 178 controls the replacement tool 142 in a similar manner to mount one or more worn parts 116 onto the roller 114. It should be understood that components of the machine controller 170 and / or control system 172 are configured to cause the roller assembly 108 to rotate the roller 114 to a desired replacement orientation in which the operator 106 and / or components of the replacement system 138 can access one or more worn parts 116 identified as needing replacement.

[0032] Components of machine controller 170 and / or control system 172 communicate with and / or are otherwise operably connected to one or more control systems and / or remote control systems of site 102 via network 180. Network 180 may be a local area network (“LAN”), a large network such as a wide area network (“WAN”), or a collection of networks such as the Internet. Protocols for network communication, such as TCP / IP, may be used to implement network 180. Although examples herein describe network 180 using, for example, the Internet, other distribution techniques may be implemented for sending information via memory cards, flash memory, or other portable storage devices. It should also be understood that various transport trucks, pavers, compactors, milling machines, excavators, wheel loaders, mining machinery, and / or other components of system 100 include corresponding controllers, and each corresponding controller communicates with and / or is otherwise operably connected via network 180. For example, network 180 may include components of a wireless communication system associated with site 102.

[0033] Network 180 can implement or utilize any desired system or protocol that includes any of the multiple communication standards. Examples of wireless communication systems or protocols that can be used by Network 180 include wireless personal area networks such as Bluetooth RTM (e.g., IEEE 802.15), local area networks such as IEEE 802.11b or 802.11g, cellular networks, or any other system or protocol for data transmission. Other wireless communication systems and configurations are considered.

[0034] Continue to refer to Figure 1 In any of the examples described herein, network 180 facilitates communication between machine controller 170 and one or more electronic devices 182. Such electronic devices 182 may include, for example, a mobile phone, laptop computer, desktop computer, tablet computer, and / or wearable device (e.g., smart glasses, smartwatch, etc.) belonging to a project manager (e.g., foreman) monitoring daily operations at site 102. One or more such electronic devices 182 include the capability to determine the degree of wear of one or more wear parts 116. As a non-limiting example, such electronic devices 182 may receive sensor data and / or other information (e.g., point cloud data, images, a set of images, or a combination thereof) generated by sensor 134. In some examples, the functionality of sensor 134 and electronic device 182 is integrated into a single device. For example, electronic device 182 may have an integrated sensor 134. In other examples, one or more electronic devices 182 receive sensor data from sensor 134 (e.g., via a physical connection, a wireless connection, and / or network 122).

[0035] Additionally or alternatively, network 180 facilitates communication between machine controller 170 and one or more site controllers 184 located remotely from machine 170. Site controllers 184 are at least partially located at site 102 (e.g., at an administrative office or command center (not shown) located at site 102). In some examples, site controllers 184 also include components located remotely from site 102, such as at a remote command center. Figure 1 In the example, site controller 184 includes one or more servers, desktop computers, processors, or other computing devices that communicate with electronic device 182 and / or machine controller 170 via network 180. Site controller 184 is substantially similar to and / or identical to the computing devices, processors, or other components described above with respect to electronic device 182 and machine controller 170. For example, site controller 184 may include a processor and memory communicatively coupled to the processor.

[0036] In some examples, the site controller 184 includes a control system 186 programmed and / or otherwise configured to quantify part wear. The control system 186 is also configured to generate wear part replacement instructions according to the implementation described herein and provide them to the control system 172 via network 180. The control system 186 includes one or more software components and / or one or more hardware components of the site controller 184, and in some examples, the control system 186 includes components substantially similar to and / or identical to those of the control system 172 described above with respect to the machine controller 170. For example, the control system 186 includes one or more components stored in the memory of the site controller 184 and configured to perform the various operations described herein. It should be understood that, additionally or alternatively, the control system 172 of the machine controller 170 also includes one or more components described herein with respect to the control system 186.

[0037] exist Figure 1 In the example shown, control system 186 includes a data processing system 188 that stores and / or otherwise includes the wear model 190, batch aggregator 192, and / or other components. Control system 186 also includes a maintenance support system 194 that stores and / or otherwise includes the part locator 196. Although the various components of control system 186 are shown as separate components and will be described separately below, the functionality of the various systems and components may differ from that discussed. Furthermore, fewer or more systems and components may be used to perform the various functions described herein. The memory of site controller 184 may also include data storage, which includes models such as the wear model 190 shown. Furthermore, it is contemplated that the wear model 190, batch aggregator 192, part locator 196, and / or other components of control system 186 may additionally or alternatively be accessible to site controller 184 via network 180 (e.g., stored in memory remote from site controller 184 or otherwise accessible thereto).

[0038] The data processing system 188 is substantially similar to and / or identical to the data processor 174 described above with respect to the control system 172. For example, Figure 1The data processing system 188 shown is configured to communicate via network 180 with one or more of machine controller 170, sensors 134, 168, and / or electronic devices 182. The data processing system 188 is typically configured to receive sensor data and / or other information generated by sensors 134, 168, and determine whether the worn part 116 needs replacement. The example considers evaluating sensor data from sensor 134 relative to a wear model 190, such as point cloud data, video data, images, or multiple images of the worn part 116. The example also anticipates that the wear model 190 is at least partially based on a custom mathematical model of wear, predicted wear, acceptable wear, wear patterns, or combinations thereof. The example also envisions that the wear model 190 is at least partially based on one or more machine learning algorithms and / or models. For example, in Figure 1 In these examples, wear model 190 provides an indication that worn part 116 needs to be replaced, at least in part, based on sensor data from sensor 134. In these examples, wear model 190 can generate instructions for replacing worn part 116, and these instructions can be executed by carrier component controller 176 and / or replacement tool controller 178 to facilitate replacement of worn part 116 by replacement system 138. Wear model 190 can also generate an estimated time until worn part 116 needs to be replaced, and can generate one or more notifications including this information. Such notifications can be output by display 179.

[0039] In some examples, the wear model 190 employed by the data processing system 188 is based on training data. For example, the training data includes information about the worn parts 116, including but not limited to one or more images of each worn part 116, specifications regarding whether a particular worn part 116 should be replaced, the usage time of a particular worn part 116, the model or serial number identifying the particular worn part 116, the manufacturer of the worn part 116, and other information. Based at least in part on this training data, the wear model 190 is generated, improved, or customized to suit the machine, the machine model, the machine type, the machine's operating environment, the machine's configuration, etc.

[0040] Alternatively or alternatively, depending on the configuration of system 100, different machines 104 may be configured with different tools. For example, in a first environment, the road milling machine is configured with a first roller (e.g., a competing rotor, a shovel rotor, or a variable bit density) fitted with a first-type tool holder that holds a first-type tool. In a second environment, the road milling machine is configured with a second roller fitted with a second-type tool holder that holds a second-type tool. In a third environment, the road milling machine is configured with either a first or second roller and fitted with first and / or second-type tool holders that hold first and / or second-type tools. In these examples, the wear model 190 is customized for each configuration of machine 104 or a representative configuration of machine 104. Additionally or optionally, the wear model 190 is customized to suit individual tool and tool holder configurations. For example, a first position on a mill fitted with a first-type tool holder that holds a first-type tool is monitored and / or evaluated using the first wear model 190, while a second position on a mill fitted with a second-type tool holder that holds a second-type tool is monitored and / or evaluated using the second wear model 190.

[0041] Additionally or alternatively, the data processing system 188 may also be configured to receive sensor data and / or other information generated by at least one of the sensors 134, 168, and determine which wear model 190 is applicable. An example considers evaluating sensor data from sensor 134, such as point cloud data of machine 104, video, images or multiple images, the configuration of roller 114, worn parts 116, tool holders, etc., to determine the wear model 190. In this example, the determined wear model 190 is then applied to the configuration of machine 104 to determine wear.

[0042] The batch aggregator 192 of the data processing system 188 includes components configured to collect, store, and / or analyze sensor data and / or other information received from sensor 134 and / or sensor 168 at regular, predictable, or predetermined intervals, such as expected inspection cycles. In these examples, the batch aggregator 192 combines this received information to further evaluate the output from the wear model 190 and / or wear trends or other patterns associated with the wear parts 116 used by the roller assembly 108. For example, when the wear model 190 generates an estimated time until a particular wear part 116 will need to be replaced (e.g., the wear duration of wear part 116), the batch aggregator 192 groups the particular wear part 116 with other wear parts having similar estimated times until replacement is required, or groups wear parts with wear durations that end before the next inspection, predicted inspection, or estimated inspection. For example, based on the collected data, the wear model 190 determines that a first wear part 116 has a first wear duration, a second wear part 116 has a second wear duration, and a third wear part 116 has a third wear duration. In this example, the duration of the first and second wear parts may be less than the expected inspection cycle or may end before the next inspection, while the duration of the third wear part may be greater than the expected inspection cycle or may end after the next inspection cycle. In this case, the batch aggregator 192 gathers the first and second wear parts 116 in the first batch and the third wear parts 116 in the second batch together. In this example, the data processing system 188 returns an indication that the first and second wear parts 116 need to be replaced. The data processing system 188 retains the second batch for further processing or may mark the relevant wear parts 116 for future monitoring.

[0043] In an example of the present invention, Figure 1The data processing system 188 shown is operable to reduce the amount of downtime for machine 104 maintenance to replace worn parts 116 by identifying and inducing replacement of other worn parts 116 that may wear out before the next expected component inspection. The data processing system 188 also reduces the number of unnecessary early replacements of worn parts 116, thus preventing more complete wear of worn parts 116, and reduces the number of late replacements of worn parts 116 that could damage underlying supports or other parts of machine 104 (e.g., rollers 114). In other words, these techniques are used to avoid inaccurate wear calculations that could lead to overuse of worn parts 116, such as causing destructive failures, and / or underuse of worn parts 116, thereby increasing costs. Additionally, in any example described herein, one or more techniques described above with respect to data processing system 188, wear model 190, and / or batch aggregator 192 may be performed wholly or partially by data processor 174 and / or by other components of machine controller 170. In some such examples, data processing system 188 may be omitted.

[0044] Figure 1 The maintenance support system 194 shown represents one or more computing systems associated with a specific machine 104, machine model, machine database, machine fleet 104, or a combination thereof, configured to manage preventative maintenance, and specifically, to manage the replacement of one or more wear parts 116. In some implementations, each wear part 116 is associated with a specific machine (e.g., machine 104) and a specific location on machine 104. Information identifying a specific wear part 116, the corresponding machine 104, the corresponding location on those machines 104, etc., is determined and / or stored by a part locator 196 or other similar database. For example, the part locator 196 stores and / or categorizes information indicating a specific location on roller 114 corresponding to a specific wear part 116, as well as information indicating a specific vehicle identification number, license plate number, or other identifier uniquely identifying machine 104. The part locator 196 may also aggregate this information across multiple databases, platforms, fleets, etc., or combinations thereof. Additionally or optionally, in various examples, the data stored by the part locator 196 is provided to the operator 106 via a display 179 and a network 180.

[0045] Continue to refer to Figure 1In some examples, system 100 also includes a parts supply and a parts return 199. The parts supply 198 and parts return 199 typically include one or more cabinets, racks, containers, sleeves, or other components configured to store new wear parts 116 (in the case of parts supply 198) and removed / worn wear parts 116 (in the case of parts return 199). In some examples, parts supply 198 and parts return 199 are attached to and / or otherwise supported by frame 120 and positioned close to replacement system 138. In such examples, parts supply 198 and parts return 199 are easily accessible by replacement tool 142 and / or by carrier assembly 140, and replacement tool 142 is configured to store removed wear parts 116 in parts return 199 when removed from roller 114. Similarly, the replacement tool 142 is configured to remove a new worn part 116 from the parts supply 198, such that the replacement tool 142 can mount the removed worn part 116 onto the roller 114 at a desired location. Alternatively, in other examples, the parts supply 198 and parts return 199 include components of a support assembly and / or are carried by the support assembly. In such examples, the replacement tool 142 can store the worn part 116 in the parts return 119 and remove the worn part 116 from the parts supply 198 more quickly, without, for example, manipulating to one or more locations on the frame 120 where the parts supply 198 and / or parts return 199 are positioned.

[0046] The following will refer to Figure 2 A more detailed description of the example components for replacing system 138 will be provided, and references will be made. Figure 3 and Figure 4 An additional example replacement system is described. It should be understood that any replacement system described herein may be used to help identify one or more worn parts 116 that need to be replaced and to facilitate the removal of such worn parts 114 from the roller 114.

[0047] Figure 2 Show in more detail Figure 1 Example of replacing a component in system 138. For example... Figure 2 As shown, an example orientation device 144 of the replacement system 138 includes a housing 202 configured to cooperate with the replacement tool 142 and to carry and / or otherwise support one or more actuators 204. (Refer to the above...) Figure 1 The orientation device 144 is configured to move the changing tool 142 along one or more tracks 146 supported by the frame 120. Figure 2 The directions indicated by arrows 206 and 208 are substantially parallel to the longitudinal axis 122 of the roller 114. Therefore, the direction indicated by arrow 206 is parallel to that indicated by arrow 148. Figure 1 The direction indicated by arrow 208 is the same as that indicated by arrow 150. Figure 1 The directions indicated by arrows 206 and 208 are the same. In any example described herein, the actuator 204 of the orientation device 144 is configured to move the housing 202 of the orientation device 144 along the track 146 in the directions of arrows 206 and 208, and thus move the replacement tool 142 connected to the housing 202. For example, the actuator 204 includes one or more electric motors (e.g., servo motors), pneumatic actuators, hydraulic cylinders, or other components mounted to and / or otherwise supported by the housing 202 of the orientation device 144 and configured to move the replacement tool 142 relative to the frame 120, rollers 114, one or more wear parts 116, etc.

[0048] The orientation device 144 also includes one or more actuators 210 (e.g., one or more additional actuators 210) configured to rotate the replacement tool 142 relative to one or more worn parts 116 of the roller 114. For example, such actuators 210 are configured to rotate the replacement tool 142 about a longitudinal axis 122′. Figure 1 Rotate clockwise 130′ and / or counterclockwise 132′ to help align the replacement tool 142 with one or more worn parts 116. It should be understood that... Figure 1 The clockwise direction 130' shown corresponds to Figure 2 The clockwise direction shown is 236, and Figure 1 The counterclockwise direction 132' shown corresponds to Figure 2 The counterclockwise direction is shown as 238.

[0049] The orientation device 144 also includes one or more electric motors (e.g., servo motors), pneumatic actuators, hydraulic cylinders, or other actuators 210 (e.g., one or more additional actuators 210) configured to rotate the replacement tool 142 relative to axis 124'. For example, such actuators 210 are configured to rotate the replacement tool 142 about axis 124' in a clockwise direction 152 and / or a counterclockwise direction 154 to help align the replacement tool 142 with one or more worn parts 116. The orientation device 144 also includes one or more additional actuators 210 configured to move the replacement tool 142 in the direction of arrow 156 and / or in the direction of arrow 158. Thus, in such an example, the actuators 210 of the orientation device 144 are configured to move the replacement tool 142 toward and / or away from the roller 114 in a direction generally parallel to the first transverse axis 124.

[0050] Furthermore, the orientation device 144 includes one or more actuators 210 (e.g., one or more additional actuators 210) configured to rotate the replacement tool 142 relative to axis 128'. For example, such actuators 210 are configured to rotate the replacement tool 142 about axis 128' in a clockwise direction 160 and / or a counterclockwise direction 162 to aid in aligning the replacement tool 142 with one or more worn parts 116. The orientation device 144 also includes one or more actuators 210 configured to be aligned in the direction of arrow 164 and / or in the direction of arrow 166 (…). Figure 1 The changing tool 142 is moved in the direction of the direction. Therefore, in such an example, the actuator 210 of the orientation device 144 is configured to move the changing tool 142 toward and / or away from the roller 114 in a direction generally parallel to the second transverse axis 124.

[0051] In some examples of the invention, the orientation device 144 includes a single housing 202 configured to receive, support, and / or otherwise carry each of the actuators 204, 210 described herein. In other examples, the orientation device 144 includes a first housing 202 configured to carry at least one of the actuators 204, 210 associated with moving the orientation device 144 along one or more tracks 146. In such an example, the orientation device 144 includes one or more additional housings 212 connected to the housing 202 and configured to carry at least one of the additional actuators 204, 210 described herein. In such an example, the housing 212 is fixedly connected to the housing 202, and one or more actuators 210 carried by the housing 212 are configured to move the replacement tool 142 relative to the housing 202. On the other hand, in another example, housing 212 is movably connected to housing 202, and in such an example, the movement of the replacement tool 142 of the various actuators 210 carried by housing 212 can cause a considerable movement of housing 212 relative to housing 202.

[0052] In any of the examples described herein, the replacement tool 142 is removably connected to at least one of housings 202, 212. For example, the replacement tool 142 includes a base 214 configured to support various components of the replacement tool 142 during the removal and / or installation of one or more worn parts 116. In such examples, the base 214 includes a substantially rigid housing, plate, platform, and / or other structures configured to mate with housing 212 and / or housing 202. For example, the base 214 includes one or more tabs, clamps, channels, fittings, through holes, flanges, and / or other means configured to engage with one or more corresponding devices of housing 212. Figure 2In one example, the replacement tool 142 includes an actuator 216 supported by a base 214 and configured to move one or more components of the replacement tool 142 relative to the base 214. For example, the actuator 216 may include one or more electric motors (e.g., servo motors), pneumatic actuators, hydraulic cylinders, or other actuation devices configured to move the first assembly 218 of the replacement tool 142 relative to the base 214. In such an example, the actuator 216 is configured to move the first assembly 218 and / or components of the replacement tool 142 connected thereto along an axis 220 (e.g., a central longitudinal axis) of the replacement tool 142 in the directions of arrows 156, 158. Figure 2 As shown, the actuators 204, 210 of the orientation device 144 are configured to orient and / or otherwise move the replacement tool 142 relative to the worn part 116 carried by the roller 114, and to position the replacement tool 142 in one or more of the aforementioned replacement positions. For example, to achieve an example replacement position, the orientation device 144 moves the replacement tool 142 such that the replacement tool 142 engages at least a portion of the worn part 116, and such that the axis 220 of the replacement tool 142 is substantially collinear with the axis 145 of the worn part 116. To achieve another example replacement position, the orientation device 144 moves the replacement tool 142 such that the replacement tool 142 engages at least a portion of the worn part 116, and such that the axis 220 is set at an angle between approximately 0 degrees and approximately 140 degrees relative to the axis 145 of the worn part 116. It should be understood that, in a further example, an additional angle between axes 125, 220 is considered. In some examples, actuator 216 includes one or more hydraulic cylinders configured to expand or extend from base 214 in the direction of arrow 158 and retract relative to base 214 in the direction of arrow 156. This configuration of actuator 216 facilitates movement of first component 218 in the directions of arrows 156, 158.

[0053] In some examples, the first component 218 includes a first platform 226 connected to the actuator 216. The first platform 226 includes substantially planar, substantially rigid plates, beams, shafts, and / or other components configured to support various components of the replacement tool 142 connected thereto and to withstand impacts, vibrations, stresses, strains, torques, loads, and / or other forces associated with removing the worn part 116 from the roller 114 and / or mounting the worn part 116 onto the roller 114. The first component 218 also includes one or more arms 228, 230 movably connected to the first platform 226 and configured to engage, contact, grip, and / or otherwise cooperate with at least a portion of the roller 114 or with one or more components connected to the outer surface 118 of the roller 114. Figure 2As shown, one or both of the arms 228 and 230 extend laterally from the first platform 226 substantially in the direction of arrow 158. With this configuration, the arms 228 and 230 extend from the first platform 226 toward the roller 114, while the changing tool 142 engages with the wear part 116. For example, the first assembly 218 includes an actuator 232 configured to move the arm 228 relative to the first platform 226, and also includes an actuator 234 configured to move the arm 230 relative to the first platform 226. As described above with respect to at least actuator 210, actuators 232 and 234 are configured to rotate the arms 228 and 230 relative to the first platform 226 to assist in engaging one or more parts disposed on the outer surface 118 of the roller 114. For example, actuator 232 is configured to rotate arm 228 in a clockwise direction 236 to engage one or more such parts, while actuator 234 is configured to rotate arm 230 in a counterclockwise direction 238 to engage such parts. Similarly, actuator 232 is configured to rotate arm 228 counterclockwise 238 to disengage from these components, while actuator 234 is configured to rotate arm 230 clockwise 236 to disengage from these components.

[0054] Arm 228 includes an end portion 240 disposed opposite to the first platform 226 and / or opposite to the actuator 232. Similarly, arm 230 includes an end portion 242 disposed opposite to the first platform 226 and / or opposite to the actuator 234. End portion 240 includes an end actuator 244, and end portion 242 includes an end actuator 246. In such an example, end actuators 244, 246 include the distal end, tip, and / or other portions of their respective arms 228, 230, which are configured to engage, contact, grip, and / or otherwise cooperate with at least a portion of the roller 114 or with one or more components attached to the outer surface 118 of the roller 114. For example, as Figure 2As shown, the roller 114 includes one or more base blocks 248 fixedly connected to the outer surface 118 of the roller 114. Each corresponding base block 248 is configured to support one or more additional components configured to removably connect a corresponding wear part 116 to the roller 114. For example, the base block 248 includes a substantially rigid base, platform, and / or other structures welded, bolted, and / or otherwise connected to the roller 114 to fix the position of the corresponding wear part 116 relative to the outer surface 118. For example, as will be described below, a part retainer is fixedly connected to the base block 248, and the part retainer includes channels, recesses, and / or other components configured to retain at least a portion of the wear part 116 when it is removably connected to the roller 114. In any of the examples described herein, base block 248 includes one or more recesses 250, 252, shelves, flanges, tabs, extensions, pawls, channels, ridges, or other components that engage with arms 228, 230 when removing worn parts 116 from roller 114 and / or installing new worn parts 116 on roller 114. Figure 2 In the example shown, when the replacement tool 142 removes the worn part 116 from the roller 114, at least a portion of the end 240 (e.g., at least a portion of the end actuator 244) engages with, is at least partially disposed within, contacts, and / or otherwise mates with the recess 250. Similarly, when the replacement tool 142 removes the worn part 116 from the roller 114, at least a portion of the end 242 (e.g., at least a portion of the end actuator 246) engages with, is at least partially disposed within, contacts, and / or otherwise mates with the recess 252.

[0055] exist Figure 2In some examples, the replacement tool 142 also includes an actuator 254 supported by a first platform 226 and configured to move one or more additional components of the replacement tool 142 relative to the base 214. For example, the actuator 254 may include one or more electric motors (e.g., servo motors), pneumatic actuators, hydraulic cylinders, or other actuation devices configured to move a second component 256 of the replacement tool 142 relative to the base 214 and / or relative to the first platform 226 of the first component 218. In these examples, the actuator 254 is substantially similar to and / or identical to the actuator 216. For example, the actuator 254 may be configured to move the second component 256 and / or components of the replacement tool 142 attached thereto along the axis 220 of the replacement tool 142 in the directions of arrows 156, 158. In some examples, actuator 254 includes one or more hydraulic cylinders configured to extend or retract from first platform 226 in the direction of arrow 158 and retract relative to first platform 226 in the direction of arrow 156. This configuration of actuator 254 facilitates movement of second assembly 256 relative to first assembly 218 in the directions of arrows 156 and 158. This movement of second assembly 256 relative to first assembly 218 facilitates removal of wear part 116 from roller 114 and / or mounting of wear part 116 onto roller 114.

[0056] In some examples, the second component 256 includes a second platform 258 connected to the actuator 254. The second platform 258 is substantially similar to and / or identical to the first platform 226. For example, the second platform 258 includes substantially planar, substantially rigid plates, beams, shafts, and / or other components configured to support various components of the replacement tool 142 connected thereto and to withstand impacts, vibrations, stresses, strains, torques, loads, and / or other forces associated with removing the wear part 116 from the roller 114 and / or mounting the wear part 116 onto the roller 114. The second component 256 also includes one or more arms 260, 262 movably connected to the second platform 258 and configured to engage, contact, grip, and / or otherwise cooperate with at least a portion of the wear part 116 when it is removed from the roller 114. Figure 2 As shown, one or both of the arms 260 and 262 extend laterally from the second platform 258 in the direction of arrow 158. With this configuration, the arms 260 and 262 extend from the second platform 258 toward the roller 114, while the changing tool 142 engages with the wear part 116.

[0057] The second component 256 also includes an actuator 264 configured to move the arm 260 relative to the second platform 258, and an actuator 266 configured to move the arm 262 relative to the second platform 258. As described above with respect to at least actuator 210, actuators 264, 266 are configured to rotate the arms 260, 262 relative to the second platform 258 to facilitate engagement of one or more wear parts 116 removably connected to the roller 114. For example, actuator 264 is configured to rotate arm 260 clockwise 236 to engage one or more such wear parts 116, and actuator 266 is configured to rotate arm 262 counterclockwise 238 to engage such wear parts 116. Similarly, actuator 264 is configured to rotate arm 260 counterclockwise 238 to disengage such wear parts 116, and actuator 266 is configured to rotate arm 262 clockwise 236 to disengage such wear parts 116.

[0058] Arm 260 includes an end portion 268 disposed opposite to the second platform 258 and / or opposite to the actuator 264. Similarly, arm 262 includes an end portion 270 disposed opposite to the second platform 258 and / or opposite to the actuator 266. End portion 268 includes an end effector 272, and end portion 270 includes an end effector 274. In such an example, end effectors 272, 274 include the distal end, tip, and / or other portion of each arm 260, 262, which are configured to engage, contact, grip, and / or otherwise cooperate with at least a portion of the wear part 116. For example, as Figure 2 As shown, the wear part 116 includes one or more shelves, flanges, tabs, extensions, pawls, channels, ridges, washers 276 and / or other components, with arms 260, 262 engaging with these components when the wear part 116 is removed from the roller 114 and / or when a new wear part 116 is installed on the roller 114.

[0059] exist Figure 2 In the example shown, the wear part 116 includes an annular washer 276 movably disposed on a spring clip 278 of the wear part 116. For example, the spring clip 278 includes a substantially hollow, substantially cylindrical shaft or other such component, and the spring clip 278 includes a spring or other biasing member disposed therein. This biasing member biases the washer 276 towards the proximal end of the wear part 116 (e.g., when the wear part is such as...). Figure 2When oriented as shown (in the direction of arrow 158), and away from the distal tip 280 of the wear part 116. The distal tip 280 includes a diamond tip, a hardened steel tip, and / or other configurations, and is configured to engage and act on the work surface 110 during use of the roller 114. When the wear part 116 is mounted into the part holder 282, which is fixedly connected to the base block 248, the contact between the washer 276 and the part holder 282 causes the washer to move distally toward the distal tip 280. For example, when the spring clip 278 is positioned within the recess 284 of the part holder 282 by moving it toward the base block 248 (e.g., in the direction of arrow 156), the washer 276 engages the part holder 282, and the part holder 282 moves the washer 276 relative to the spring clip 278 in the direction of arrow 156.

[0060] The second component 256 also includes a cup 286 configured to engage the distal tip 280, the washer 276, and / or other components of the wear part 116. Figure 2 In the example, cup 286 is fixedly or movably mounted to the second platform 258, and cup 286 includes a recess 288, the shape, size, and / or other configuration of which is to receive at least a portion of the distal tip 280 when the replacement tool 142 engages with the worn part 116. For example, as Figure 2 As shown, the first end 290 of the cup 286 is fixedly or movably connected to the second platform 258, and the cup 286 includes a generally conical and / or generally dome-shaped internal recess 288 extending from the second end 292 of the cup 286 toward the first end 290. Such a recess 288 is configured to substantially receive the entire distal tip 280 of a new, unworn wear part 116.

[0061] When this new wear part 116 is installed into the part holder 282 and / or onto the roller 114, the end actuators 272, 274 of the arms 260, 262 engage the washer 276 and push the washer 276 in the direction of arrow 156, such that the washer 276 and / or at least a portion of the distal tip 280 remains in contact with the end 292 of the cup 286. In such an example, the cup 286 may move relative to the second platform 258 and / or relative to the ends 268, 270 in the direction of arrow 158 to aid in engagement of the wear part 116. Alternatively or additionally, when the new wear part 116 is installed into the part holder 282, the end actuators 272, 274 may move relative to the second platform 258 and / or relative to the cup 286 in the direction of arrow 156 to aid in engagement of the wear part 116. When the wear part 116 is installed or removed, the second platform 258 may move relative to the first platform 226 in the direction of arrows 156, 158. Additionally or alternatively, when installing or removing worn part 116, the first platform 226 may move relative to the second platform 258 in the directions of arrows 156 and 158. (See reference...) Figure 2 The components of the described replacement tool 142 and the relative movement of these components facilitate the removal and installation of the worn part 116 in any of the examples described herein. Furthermore, such a replacement tool 142 is configured for use with any replacement system described herein. It should be understood that the aforementioned replacement tool 142 and replacement system 138 are configured to remove and install such worn part 116 in a manner that minimizes downtime of machine 104. Therefore, the aforementioned replacement system 138 improves site efficiency and can minimize maintenance costs associated with worn part failure and / or premature replacement of worn part 116. Replacement system 138 also improves site safety by reducing the risk of injury associated with manually replacing such worn part 116.

[0062] Figure 3 An additional replacement system 300 of the present invention is shown, in which such a replacement tool 142 is employed. The replacement system 300 includes a carrier assembly 302 having a guiding device 304 configured to move the replacement tool 142 in multiple directions relative to one or more worn parts 116 removably connected to a roller 114. Figure 3 In the example shown, at least a portion of the carrier component 302 is movably connected to the machine 104. Figure 1The frame 120 of the replacement system 300. In such an example, one or more components of the replacement system 300 can be moved, for example, semi-manually or fully manually, by the operator 106 relative to the frame 120. For example, the carrier assembly 302 includes one or more links, and at least one link is movably connected to the frame 120 and / or other components of the carrier assembly 302 by one or more actuators similar to the actuators 204, 210 described above. In this “semi-manual” example, these actuators are configured to at least partially assist the operator 106 in moving the replacement tool 142 and / or other components of the carrier assembly 302 while removing the worn part 116 from the roller 114 and / or simultaneously mounting such worn part 116 onto the roller 114. On the other hand, in the “fully manual” example of the replacement system 300, such actuators are omitted.

[0063] like Figure 3 As shown, an example orientation device 304 of the replacement system 300 includes one or more handles 306 that can be manipulated or otherwise "gripped" by an operator 106 to help the operator 106 ideally position the replacement tool 142. Such handles 306 extend from the orientation device 304. In such an example, relative to... Figure 2 The various actuators 204, 210 indicated in the example orientation device 144 are omitted from the orientation device 304.

[0064] Furthermore, the load-bearing assembly 302 of the replacement system 300 includes a link 308 movably connected to the frame 120 of the machine 104 via a joint 310. The link 308 includes one or more shafts, beams, rods, and / or other substantially rigid structures configured to support the weight of the replacement tool 142 and / or other components of the load-bearing assembly 302, which are movably mounted to the frame 120. The joint 310 includes, for example, one or more bearings, bushings, ball joints, and / or other such fittings configured to allow full freedom of movement and / or range of motion between the link 308 and the frame 120. The load-bearing assembly 302 may include one or more additional link-joint configurations as needed to provide optimal freedom of movement for the replacement tool 142 relative to the frame 120. For example, as... Figure 3 As shown, the support assembly 302 also includes a link 312 movably connected to the link 308 via a connector 314. In some examples, a replacement tool 142 is movably connected to the link 312 and is manually movable relative to the frame 120. In some examples, the support assembly 302 also includes a link 316 movably connected to the link 312 via a connector 318. In any such example, the housing of the orientation device 304 is fixedly or movably connected to one or more of the aforementioned links 308, 312, and 316, and the replacement tool 142 is connected to the housing of the orientation device 304.

[0065] In such an example, replacement system 300 provides additional means for removing one or more worn parts 116 from roller 114 and / or for mounting one or more such worn parts 116 onto roller 114. In addition to one or more aspects described above with respect to replacement system 138, Figure 3 The replacement system 300 also reduces operator fatigue associated with removing worn parts 116 from roller 114 and / or installing new worn parts 116. As a result, operator safety and efficiency are improved.

[0066] Figure 4 Another example of the replacement system 400 of the present invention is shown, in which a replacement tool 142 is used. The replacement system 400 includes a carrier assembly 402 having a guiding device 404, the guiding device 404 being configured to move the replacement tool 142 in multiple directions relative to one or more worn parts 116 removably connected to a roller 114. Figure 4 In the example shown, the carrier assembly 402 includes an autonomous rovers 406 operatively connected to machine controller 170, one or more electronic devices 182, and / or site controller 184. For example, rovers 406 includes a controller 408 operatively connected via network 180 to machine controller 170 and / or the aforementioned devices / controllers. Rovers 406 are configured to traverse work surface 110 at site 102 to aid in locating replacement tools 142 relative to one or more worn parts 116 requiring replacement. Figure 4 The directional device 404 shown is configured to move the replacement tool 142 relative to the worn part 116 in any of the aforementioned ways, and the directional device 404 is at least related to the above. Figure 2 The described orientation device 144 is substantially similar and / or identical. For example, orientation device 404 includes one or more actuators configured to move orientation device 404 relative to such worn part 116, and / or configured to move replacement tool 142. Figure 4 In the example, the orientation device and / or other controllable components of the replacement system are operatively connected to the controller 408 of the rovers 406, and the controller 408 is configured to control its operation to remove one or more wear parts 116 from the roller 114 and / or install one or more wear parts 116 on the roller 114.

[0067] Figure 4The rovers 406 shown include any on-road or off-road vehicle configured to controllably traverse a portion of the work surface 110 and occupy a location where the changing tool 142 can access and removably attach one or more wear parts 116 to the roller 114. In some examples, the rovers 406 include semi-autonomous or fully autonomous machines that can be controlled at least in part based on instructions received by the controller 408 from the machine controller 170, electronics 182, and / or site controller 184. The rovers 406 include a set of wheels, tracks, or other ground engagement elements, and a power source for driving the movement of such ground engagement elements. The power source is at least one of a conventional internal combustion engine operating on fossil fuels or mixed fuels and an electrically operated drive powered by alternative energy sources such as batteries, solar energy, etc. The controller 408 of the rovers 406 is substantially similar to and / or identical to the machine controller 170 and / or site controller 184 described above, and the controller 408 includes one or more processors, memory and / or other components included in the machine controller 170 and / or site controller 184.

[0068] The rovers 406 also include communication devices (not shown) and position sensors (not shown) operatively and / or otherwise connected to the controller 408. The communication devices are configured to allow wireless transmission of various signals, commands, and / or information between the controller 408 and, for example, machine controller 170 and / or site controller 184. The communication devices include a transmitter configured to send signals to a receiver, for example, machine controller 170 and / or site controller 184. The communication devices also include a receiver configured to receive such signals. In some examples, the transmitter and receiver of the communication devices are combined into a transceiver or other such components. In any of the examples described herein, the communication devices enable communication between the controller 408 and other system components via network 180.

[0069] The position sensor of rover 406 is configured to determine the position and / or orientation of rover 406 at site 102. In some examples, the position sensor includes components of a Global Navigation Satellite System (GNSS) or Global Positioning System (GPS). Alternatively, a Universal Total Station (UTS) is used to locate the corresponding position of rover 406. In some examples, the position sensor of rover 406 includes a GPS receiver, transmitter, transceiver, laser prism, and / or other such devices, and the position sensor communicates with one or more GPS satellites and / or UTS to determine the corresponding position of rover 406 continuously, substantially continuously, or at various time intervals. In such examples, machine 104 may also include a similar position sensor communicating with one or more GPS satellites and / or UTS, and such GPS satellites and / or UTS are also configured to determine the corresponding position of machine 104. In any of the examples described herein, the position determined by the corresponding position sensor may be used by controller 408, machine controller 170, site controller 184 and / or other components of system 100 to coordinate the activities of machine 104, rovers 408 and / or other components of system 100.

[0070] In any of the examples described herein, controller 408, machine controller 170, electronics 182, site controller 184, and / or other components of system 100 are operable to control various components of system 100 in manual, semi-autonomous, and / or fully autonomous operating modes. In an example of fully autonomous operating mode, the controller of the corresponding component of system 100 at least partially controls steering, speed, acceleration, deceleration, drum height, drum speed, orientation device operation, tool change operation, rover operation, and / or other functions of these components without input from operator 106. In such an example, and as described above, rover 406 includes an autonomous rover 406. In an example of semi-autonomous operating mode, the controller of the corresponding component of system 100 at least partially controls one or more such functions without input from operator 106, but in such an operating mode, operator 106 is able to assist or override instructions from the controller before or during the execution of such functions. In the example manual operation mode, operator 106 manually controls the execution of these functions, but the controllers of the corresponding components of system 100 periodically and / or temporarily control the execution of these functions (e.g., controlling the speed of components of system 100 in "cruise control").

[0071] Continue to refer to Figure 4The rovers 406 also include at least one sensor 410 configured to capture sensor data or other information associated with the roller 114. As described above, such sensor data includes, for example, position information, orientation information, video, and / or one or more images (e.g., still images) of one or more wear parts 116 removably attached to the roller 114. In this example, sensor 410 is substantially similar to and / or identical to sensor 134 described above, and sensor 410 also has a corresponding field of view 412. For example, sensor 410 may be an optical sensor, a two-dimensional digital camera, a three-dimensional digital camera, or a ranging sensor, including but not limited to radar sensors, LiDAR sensors, time-of-flight sensors, high-speed imaging devices, etc. In such an example, sensor 410 captures sensor data including video and / or images showing one or more wear parts 116 disposed on the roller 114. Sensor 410 sends such sensor data to controller 408, and controller 408 uses such sensor data to help navigate rovers 408 to a location close to the roller 114, where replacement tool 142 can approach one or more of the shown wear parts 116 for removal. Additionally, similar to the above references Figure 1 In the described process, controller 408 and / or machine controller 170 utilize sensor data received from sensor 410 to perform one or more wear models. In doing so, controller 408 and / or machine controller 170 are configured to identify one or more worn parts 116 that require replacement. Controller 408 and / or machine controller 170 may also provide an indication that one or more worn parts 116 need replacement, at least in part, based on sensor data received from sensor 410. In some examples, controller 408 and / or machine controller 170 utilize such wear models to generate an estimated time (e.g., wear duration) until one or more worn parts 116 detachably connected to roller 114 will require replacement. In any of the examples described herein, controller 408 and / or machine controller 170 may employ one or more object recognition algorithms or other procedures to aid in the identification and / or classification of objects such as roller 114, one or more worn parts 116, etc.

[0072] exist Figure 4In one example, sensor 410 includes a first sensor carried by rovers 406, which communicates with and / or is otherwise operatively connected to controllers 408, 170, 182, and / or 184. In such an example, carrier assembly 402 may also include one or more additional sensors that communicate with one or more of the aforementioned controllers and are movable with the change tool 142. For example, carrier assembly 402 may also include sensor 414 that communicates with controllers 408, 170, 182, and / or 184 and is movable with the change tool 142. In such an example, sensor 414 is substantially similar to and / or identical to the sensors described above. Figure 1The sensor 168 is described. For example, sensor 414 may capture sensor data including positional information, orientation information, video, and / or one or more images of the worn part 116, and the sensor data captured by sensor 414 may be used to assist in the removal of one or more worn parts 116. For example, controller 408 is configured to receive video, images, and / or other sensor data captured by sensor 414. Controller 408 is also configured to use such sensor data to identify one or more worn parts 116 removably attached to roller 114 that need to be replaced. In any example described herein, controller 408 and / or machine controller 170 input such sensor data into an image recognition engine, algorithm, model, or other component. These components identify one or more worn parts 116 that need to be replaced based on the received sensor data. Controller 408 and / or machine controller 170 use outputs from these components to control the movement of replacement tool 142 via orientation device 144. In particular, controller 408 uses sensor data received from sensor 414 and / or outputs received from the image recognition engine or the other components described above to control the operation of orientation device 404. This operation includes moving the replacement tool 142 to one or more replacement locations as described herein. For example, this operation includes moving the replacement tool 142 such that its axis is substantially collinear with axis 145, and such that one or more arms, cups, end effectors, or other components of the replacement tool 142 engage with a specific identified wear part 116. The controller 408 and / or machine controller 170 also use sensor data and / or other information from sensor 414 to confirm that the replacement tool 142 is properly engaged with and / or otherwise positioned relative to the roller 114 and / or wear part 116, making it controllable to remove the wear part 116 from the roller 114. In such an example, sensor data received from sensor 404 enables the controller 408 to control the movement and operation of the orientation device 404 and / or the replacement tool 142 when removing the wear part 116 from the roller 114 and / or when mounting the wear part 116 onto the roller 114.

[0073] The controller 408 also uses sensor data received from sensor 414 to control one or more other components of the support assembly 402. For example, the support assembly 402 includes one or more links, and at least one link is movably connected to the frame rovers 406 and / or other components of the support assembly 402 via one or more actuators similar to the actuators 204, 210 described above. Such actuators are configured to control the movement of the various links relative to the frame of the rovers 406. For example, the support assembly 402 includes a link 416 movably connected via a joint 418 to the substantially rigid frame and / or other parts of the rovers 406. Link 416 is substantially similar to and / or identical to those described above. Figure 3 The described link 308. For example, link 416 includes one or more shafts, beams, rods, and / or other substantially rigid structures configured to support the weight of the replacement tool 142 and / or other components of the load-bearing assembly 402, which are movably mounted to the rovers 406. Connector 418 includes, for example, one or more bearings, bushings, ball joints, and / or other fittings configured to allow full freedom of movement and / or range of motion between link 416 and the portion of rovers 408 to which link 416 is mounted. Additionally or alternatively, connector 418 includes one or more actuators similar to and / or identical to the actuators 204, 210 described above.

[0074] The support assembly 402 may include one or more additional link-joint configurations as needed to provide optimal degrees of freedom of movement for the replacement tool 142 relative to the rovers 406. For example, as Figure 4 As shown, the carrier assembly 402 also includes a link 420 movably connected to the link 416 via a connector 422. In some examples, a replacement tool 142 is movably connected to the link 420. In some examples, the carrier assembly 402 also includes a link 424 movably connected to the link 420 via a connector 426. In any such example, the housing of the orientation device 404 is fixedly or movably connected to one or more of the aforementioned links 416, 420, 424, and the replacement tool 142 is connected to the housing of the orientation device 404. In these examples, links 420, 424 are substantially similar to and / or identical to link 416, and connectors 422, 426 are substantially similar to and / or identical to connector 418. Thus, in such examples, the replacement system 400 provides a means for removing one or more worn parts 116 from the roller 114 and / or for mounting one or more such worn parts 116 onto the roller 114. Similar to the above regarding... Figure 1-4The replacement system and other components described herein, replacement system 400, assist in performing these tasks in a manner that minimizes downtime of machine 104 associated with replacing worn parts 116. As a result, replacement system 400 improves site efficiency and can minimize maintenance costs associated with failure of worn parts and / or premature replacement of worn parts 116. Replacement system 400 also improves site safety by reducing the risk of injury associated with manually replacing such worn parts 116.

[0075] Figure 5 A flowchart describing an example method 500 is shown, which involves removing a worn part 116 from a roller 114 and installing a new worn part 116 at a suitable position on the roller 114. Example method 500 is shown as a set of steps in a logic flowchart, where each step represents an action or operation implemented in hardware, software, or a combination thereof. In the context of software, these steps represent computer-executable instructions stored in memory. When these instructions are executed by one or more processors, such as machine controller 170, electronic device 182, site controller 184, controller 408, and / or other controllers or processors described herein, these instructions cause these components to perform the said action or operation. Typically, computer-executable instructions include routines, programs, objects, components, data structures, etc., that perform a particular function or implement a particular abstract data type. The order in which the operations are described is not intended to be construed as limiting, and any number of the described blocks can be combined in any order and / or in parallel to implement these processes. In some embodiments, one or more blocks of a process may be omitted entirely. Furthermore, one or more steps described with respect to method 500 may be combined in whole or in part. Additionally, in some examples, the steps of method 500 may be combined with other methods. For ease of description, method 500 will be described below with respect to system 100, machine 104, replacement system 138, machine controller 170 and / or one or more processors or other components thereof, unless otherwise stated.

[0076] At 502, machine controller 170 receives information related to roller assembly 108. For example, at 502, machine controller 170 controls sensor 134 to capture position information (e.g., coordinates), orientation information, video, one or more images, and / or other sensor data. In such an example, the sensor data captured by sensor 134 includes one or more images of a plurality of wear parts 116 removably attached to roller 114. In these examples, the plurality of wear parts 116 shown in the sensor data are positioned within the field of view 136 of sensor 134, and the images of these wear parts 116 show the surfaces of the wear parts 116 that are expected or designed to wear (e.g., wear surfaces), as well as surfaces (e.g., outer surface 118) or structures (e.g., base block 248, part holder 282, etc.) adjacent to or supporting the wear parts 116. In some examples, at 502, machine controller 170 generates and / or provides notification to operator 106 via display 179, prompting operator 106 to capture certain images of wear parts 116 or other parts of roller 114. In the example, sensor 134 is configured to capture such sensor data when roller 114 is stationary, in motion, or in motion below a threshold rotational speed. For example, at 502, when roller 114 rotates at a speed below the operating speed, sensor 134 captures sensor data including images showing multiple worn parts 116, where the operating speed is the speed at which roller 114 rotates when machine 104 is in operation.

[0077] At 504, machine controller 170 determines, at least in part, based on information received at 502, whether one or more wear parts 116 removably connected to roller 114 need replacement. For example, at 504, data processor 174 evaluates video, images, and / or other information included in sensor data to determine the presence, health, and / or condition of wear parts 116 shown in one or more images included in the sensor data. In some examples, at 504, machine controller 170 compares wear part images, contours, point cloud data, and / or other information included in the sensor data with corresponding information included in wear model 190. In some examples, at 504, machine controller 170 and / or data processing system 188 input such sensor data into wear model 190, one or more machine learning algorithms, one or more image analysis engines, and / or other evaluation models.

[0078] As mentioned above regarding at least Figure 1Based at least in part on this sensor data, wear model 190 generates and provides indications regarding whether one or more worn parts 116 in the image contained in the sensor data need to be replaced. In these examples, at 504, wear model 190 generates instructions for replacing worn parts 116, and these instructions can be executed by carrier component controller 176 and / or replacement tool controller 178 to facilitate the replacement of one or more worn parts 116 by replacement system 138. These instructions, along with machine controller 170 and / or wear model 190, can identify specific worn parts among the worn parts 116 that need to be replaced based on the sensor data. Such indications may include and / or identify the corresponding position of the specific worn part 116 that needs to be replaced on roller 114. Wear model 190 may also generate an estimated time until the worn part 116 needs to be replaced and may generate one or more notifications including this information. At 504, machine controller 170 may cause display 179 to output one or more such notifications and / or indications to identify one or more worn parts 116 that need to be replaced.

[0079] For example, at 504, data processor 174 determines whether other indications of the condition or wear status of a specific worn part 116, such as a contour, two-dimensional image, point cloud model, three-dimensional image, and / or wear model 190, exceed a corresponding replacement threshold. In this process, data processor 174 and / or wear model 190 generate an indication of such condition or wear status at 504, using sensor data received at 502. In such an example, machine controller 170 determines at 504 whether one or more of these indications exceed (e.g., are greater than) a corresponding replacement threshold, thereby indicating that the associated worn part 116 needs to be replaced.

[0080] If at 504, machine controller 170 determines that none of the worn parts 116 included in and / or identified by the sensor data received at 502 need to be replaced (504: No), then machine controller 170 returns to 502 and continues to receive information associated with roller assembly 108 and / or roller 114. On the other hand, if at 504, machine controller 170 determines that one or more of the worn parts 116 included in and / or identified by the sensor data received at 502 need to be replaced (504: Yes), machine controller proceeds to 506.

[0081] At 506, machine controller 170 moves roller 114 to a replacement orientation in which one or more worn parts identified at 504 can be accessed by replacement system 138 operably connected to machine controller 170. In some examples, at 506, operator 106 provides instructions, inputs, and / or other such requests to machine controller 170 via display 179 and / or other user interface of machine 104. In such examples, machine controller 170 causes roller assembly 108 to rotate roller 114 to the replacement orientation based at least in part on such requests. Additionally or alternatively, at 506, machine controller 170 moves roller 114 automatically and / or without input from operator 106 to replacement orientation 506.

[0082] At 508, machine controller 170 causes replacement system 138 to remove one or more worn parts 116 identified at 504. For example, at 508, machine controller 170 causes replacement tool 142 of replacement system 138 to contact, engage, and / or otherwise meet a specific worn part 116 removably attached to roller 114 and remove the worn part 116 from roller 114. In these examples, at 508, sensor 168 captures additional sensor data associated with the worn part 116 to be replaced. For example, such additional sensor data includes video, one or more images, and / or other information specific to the worn part 116. Sensor 168 directs this additional sensor data to machine controller 170.

[0083] At 508, the carrier component controller 176 positions the orientation device 144 relative to the specific worn part 116 and the replacement tool 142 to facilitate the removal of the worn part 116. For example, sensor data received at 502 and / or additional sensor data received at 508 from sensor 168 includes information indicating the position of the specific worn part 116 on the roller 114. The carrier component controller 176 controls the orientation device 144 to position the replacement tool 142 near the identified location, and in such examples, the orientation device 144 orients and / or otherwise moves the replacement tool 142 to any replacement location described herein. For example, in some examples, the orientation device 144 positions the replacement tool 142 such that the axis 220 of the replacement tool 142 is substantially collinear with the axis 145 of the worn part 116, and / or causes the replacement tool 142 to engage at least a portion of the worn part 116. As described above, positioning the replacement tool 142 in this manner particularly includes moving the replacement tool 142 along one or more tracks 146 in the direction of arrow 208 and / or arrow 206 using the orientation device 142. This positioning of the replacement tool 142 may also include rotating the replacement tool 142 using the orientation device 144, as described above. Figure 2The tool 142 is moved in a direction substantially parallel to axis 145 using the orientation device 142.

[0084] Additionally, at 508, the tool changer controller 178 rotates and / or otherwise moves the arms 228, 230 of the tool changer 142 (e.g., along axis 220) to at least partially align the end effectors 244, 246 within corresponding recesses 250, 252 of the base block 248 supporting the worn part 116. Furthermore, at 508, the tool changer controller 178 rotates and / or otherwise moves the arms 260, 262 of the tool changer 142 (e.g., along axis 220) to engage at least a portion of the washer 276 of the worn part 116 with the end effectors 272, 274. At 508, the tool changer controller 178 also moves and / or otherwise positions the cup 286 of the tool changer 142 to engage at least a portion of the tip 280 of the worn part 116 and / or at least a portion of the washer 276. When the worn part 116 is engaged as described above, at 508, the tool changer 178 moves the second component 256 of the tool changer 142 relative to the base 214 and / or relative to the orientation device 144 in the direction of arrow 156. Additionally or optionally, when the worn part 116 is engaged as described above, at 508, the tool changer 178 moves the first component 218 of the tool changer 142 relative to the base 214 and / or relative to the orientation device 144 in the direction of arrow 158. At 508, the movement of at least one of the first component 218 and the second component 256 in this manner causes the worn part 116 to disengage from the part holder 282, and thus removes the worn part 116 from the roller 114.

[0085] Although end effectors 272, 274 are described herein as engaging washer 276 to aid in removal of worn part 116 from part holder 282 at 508, in other examples, end effectors 272, 274 are configured at 508 to grip, cut into, apply opposing force to tip 280 of worn part 116, and / or otherwise engage tip 280 of worn part 116 to aid in removal of worn part 116. In such examples, cup 286 may be omitted, or may at least partially engage the distal end of tip 280, while end effectors 272, 274 directly engage tip 280. In other examples, at 508, at least one of end effectors 272, 274 is configured to approach and / or engage a component of worn part 116 at least partially disposed within part holder 282. For example, at 508, at least one of the end actuators 272, 274 engages the spring clip 278, the handle, and / or other components of the worn part 116 via an opening and / or channel (not shown) in the part holder 282. When engaged in this way, at least one of the end actuators 272, 274 applies force to the worn part 116 in the direction of arrow 156 to aid in the removal of the worn part 116 from the part holder 282. This example process for removing the worn part 116 may be useful if the washer 276 has been broken, displaced, damaged, and / or otherwise damaged.

[0086] Furthermore, in any of the examples described herein, the part holder 282 may include a worn part removably attached to the roller 114. In such examples, the part holder 282 wears over time due to the relatively harsh conditions of using the roller 114, and in such examples, one or more part holders 282 require removal and / or replacement. It should be understood that in any of the examples described herein, arms 260, 262 are also configured to assist in the removal and / or replacement of such worn part holders 282. In such examples, at 508, at least one of the end effectors 272, 274 is configured to grip the part holder 282, apply an opposing force to the part holder 282, rotate the part holder 282, and / or otherwise engage the part holder 282 to assist in the removal of the part holder 282 from the base block 248. In some such examples, the end effectors 272, 274 are configured to rotate and / or otherwise move the part holder 282 relative to the base block 248 to assist in the removal of the part holder 282. In other such examples, end effectors 272, 274 are configured to rotate and / or otherwise remove one or more pins, retaining screws, bolts, and / or other connectors configured to removably connect part holder 282 to base block 248. Additionally or optionally, at 508, at least one of end effectors 244, 246 may be configured to perform one or more of the above operations to assist in removing part holder 282 from roller 114. In such examples, arms 228, 230 are also configured to assist in removing and / or replacing such worn part holder 282.

[0087] At 510, machine controller 170 causes replacement system 138 to mount worn part 116 onto roller 114 for replacement of worn part 116 removed at 508. For example, at 510, carrier component controller 176 causes orientation device 144 to move replacement tool 142 along track 146 such that replacement tool 142 is positioned to receive new worn part 116 from parking supply 198. Once correctly positioned, replacement tool controller 178 controls replacement tool 142 to engage with worn part 116 disposed in parking supply 198, and carrier component controller 176 causes orientation device 144 to move replacement tool 142 to a position on roller 114 of removed worn part 116 (e.g., position of empty part holder 282). At 510, replacement tool controller 178 positions worn part 116 such that the central axis 145 of worn part 116 is substantially collinear with the corresponding central axis of recess 284 defined by part holder 282. When correctly positioned at 510, the spring clip 278 of the worn part 116, carried by the replacement tool 142, is positioned on and / or substantially aligned with the recess 284. At 510, the replacement tool controller 178 moves the second assembly 256 and / or the first assembly 218 in the direction of arrow 158, thereby substantially fully mounting the spring clip 278 of the worn part 116 into the recess 284. Due to the engagement between the washer 276 and at least the part holder 282 when the spring clip 278 is inserted into the recess 284 in the direction of arrow 158, the washer 276 remains stationary relative to the part holder 282 as the spring clip 278 moves in the direction of 158. In such an example, a new worn part 116 is mounted onto the roller 114 when the spring clip 278 is substantially fully seated and / or otherwise positioned within the recess 284 and the washer 276 abuts the top of the part holder 282.

[0088] At 512, machine controller 170 determines whether one or more additional wear parts 116 removably connected to roller 114 need to be replaced. In such an example, machine controller 170 performs one or more of the steps described above with respect to 504. For example, at 512, machine controller 170 and / or data processor 174 determine whether other indications of the condition or wear state of a particular wear part 116, such as contours, two-dimensional images, point cloud models, three-dimensional images, and / or other indications, exceed a corresponding replacement threshold. In this process, data processor 174 and / or wear model 190 generate an indication of such condition or wear state at 512, using sensor data received at 502 and / or 508. In such an example, machine controller 170 determines at 512 whether one or more such indications exceed (e.g., are greater than) a corresponding replacement threshold, thereby indicating that the associated wear part 116 needs to be replaced.

[0089] If at 512, machine controller 170 determines that one or more of the worn parts 116 included and / or identified by the sensor data received at 502 and / or 508 need to be replaced (512: Yes), the machine controller returns to 506. On the other hand, if at 512, machine controller 170 determines that none of the worn parts 116 included and / or identified by the sensor data received at 502 and / or 508 need to be replaced (512: No), then machine controller 170 proceeds to 514.

[0090] At 514, machine controller 170 records, processes, and / or outputs information related to one or more wear parts 116 replaced at 508 and / or installed at 510. For example, at 514, machine controller 170 records item number, serial number, SKU number, part number, and / or other identifiers that uniquely identify the wear part 116 replaced at 508 and / or installed at 510. Machine controller 170 also includes date, time, shift, wear part location (on roller 114), machine identifier, and / or other information at 514, and is associated with the wear part 116 replaced at 508 and / or installed at 510. At 514, machine controller 170 records this information in one or more data memories and / or other memory components of machine controller 170. Additionally or optionally, at 514, machine controller 170 provides this information to control system 186 via network 180. At 514, control system 186 stores this information in the memory of site controller 184. Additionally or alternatively, at 514, other components of the batch aggregator 192 and / or data processing system 188 and / or maintenance support system 194 classify, annotate, and / or otherwise process this information for current or future use. In yet another example, at 514, machine controller 170 generates one or more notifications providing such information and causes display 179 and / or one or more electronic devices 182 to display and / or otherwise output one or more such notifications via a user interface or other graphical interface.

[0091] Industrial applicability

[0092] The disclosed system and method can be applied to any site 102 or other environment where a machine 104 with one or more wear parts 116 operates on a working surface 110. By capturing sensor data illustrating such wear parts 116, the replacement system described herein determines whether one or more of the wear parts 116 shown need to be replaced. Furthermore, the replacement system of the present invention is configured to quickly and safely remove wear parts 116 as needed and replace the removed wear parts 116 with new wear parts 116. The system described herein also captures and tracks information that uniquely identifies the removed and installed wear parts, enabling machine-specific, wear part-specific, and / or site-specific trend analyses and other analyses to be performed over time.

[0093] For example, and refer to Figure 1 After the shift is completed, or at some other interval, the machine controller 170 causes the sensor 134 to capture sensor data including an image of the worn part 116 disposed on the roller 114 of the machine 104. The data processor 174 and / or the data processing system 188 use the wear model 190 to determine the amount of wear corresponding to the worn part 116. If the machine controller 170 determines that one or more of the worn parts 116 actually need to be replaced, the carrier component controller 176 and the replacement tool controller 178 control the components of the replacement system described herein to remove the identified worn part 116 and install a new worn part 116 on the roller 114 to replace the removed worn part 116.

[0094] The techniques described herein improve the efficiency of a construction site (e.g., site 102) and / or the efficiency of a machine (e.g., machine 104). By way of example and not limitation, the techniques described herein ensure that worn parts 116 are properly maintained and / or replaced, which can lead to more efficient use of machine 104, including but not limited to reduced fuel consumption and / or wear on other auxiliary machine parts. For example, when worn parts 116 are not replaced but are allowed to fail, roller 114 may begin to wear or otherwise deteriorate. In this example, replacing or repairing roller 114 is more expensive, difficult, and time-consuming than timely replacement of worn parts 116. Furthermore, the replacement system of the present invention minimizes the safety risks associated with removing and installing worn parts in harsh environments such as site 102.

[0095] Those skilled in the art will understand that computer programs for implementing the disclosed technology can be stored on and / or read from a computer-readable storage medium. The computer-readable storage medium may store computer-executable instructions that, when executed by a processor, cause the computer to perform the processes disclosed herein. Exemplary computer-readable storage media include magnetic storage devices such as hard disks, floppy disks, magnetic tapes, or other magnetic storage devices known in the art; optical storage devices such as CD-ROMs, DVD-ROMs, or other optical storage devices known in the art; and / or electronic storage devices such as E-ROMs, flash drives, or other integrated circuit storage devices known in the art. The computer-readable storage medium may be implemented by one or more components of system 100.

[0096] It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed payload overload control system without departing from the scope of the invention. Other embodiments will become apparent to those skilled in the art upon consideration of the specification and practice with respect to the embodiments disclosed herein. This specification and examples are intended to be considered merely exemplary, and the true scope of the invention is indicated by the appended claims and their equivalents.

Claims

1. A system comprising: Carrier component; The tool is replaced, which is movably supported by the carrier component; A sensor, configured to capture sensor data, is associated with a plurality of wear parts removably attached to a rotatable roller, wherein the roller: It is set on the mating side of the machine's working surface, and Configured to act on the working surface from the working surface engagement side of the machine while the machine is disposed on the working surface; and The controller includes a processor and is configured to receive sensor data from the sensor, determine the wear duration of each of the plurality of worn parts based on the sensor data, and group the plurality of worn parts based on a comparison of the wear duration with an expected inspection cycle and determine one or more worn parts that need to be replaced. This is based, at least in part, on the controller's identification of the worn parts: The carrier assembly is configured to move the replacement tool relative to the worn part, such that the replacement tool engages with the worn part, and The replacement tool is configured to remove the worn part from the roller while the roller remains positioned on the working surface engagement side of the machine.

2. The system of claim 1, wherein the carrying component includes an orientation device operably connected to the controller, the orientation device including at least one actuator and configured to move the changing tool in a direction generally parallel to the central longitudinal axis of the roller.

3. The system of claim 2, wherein the orientation device comprises a first actuator and a second actuator, the first actuator being configured to move the replacement tool along at least one fixed track, and the second actuator being configured to rotate the replacement tool relative to the worn part.

4. The system according to claim 3, wherein: The support assembly is configured to move the replacement tool such that the central longitudinal axis of the replacement tool is substantially collinear with the central longitudinal axis of the worn part. The replacement tool is configured to remove the worn part from the roller while the central longitudinal axis of the replacement tool is substantially collinear with the central longitudinal axis of the worn part, and The second actuator is configured to rotate the changing tool about an axis that extends substantially parallel to the central longitudinal axis of the drum.

5. The system of claim 2, wherein the sensor includes a first sensor, and the carrier assembly further includes a second sensor, the second sensor communicating with the controller and capable of moving with the replacement tool.

6. The system of claim 5, wherein the controller is configured to move the orientation device and control the replacement tool to remove the worn part based on the sensor data and information received from the second sensor.

7. The system according to claim 1, wherein: The wear part includes a first wear part disposed at a first position on the roller, and The replacement tool includes a single replacement tool of the system, the single replacement tool of the system being configured to: Remove the first worn part from the first position on the roller, and A second wear part is installed at the first position on the roller.

8. A method comprising: A controller receives sensor data from a sensor, the controller including a processor, and the sensor data is associated with a plurality of wear parts removably connected to a rotatable roller, wherein the roller: It is set on the mating side of the machine's working surface, and It is configured to act on the working surface from the working surface engagement side of the machine while the machine is set on the working surface; The processor is used to identify, based on the sensor data, the wear parts that need to be replaced among the plurality of wear parts, including The wear duration of each of the plurality of worn parts is determined based on the sensor data, and The multiple worn parts are grouped based on a comparison of wear duration and expected inspection cycle, and one or more worn parts that need to be replaced are identified. The controller is used to move the roller to a replacement direction, in which the worn part can be accessed by a replacement system operably connected to the controller, the replacement system including a replacement tool; as well as The controller is used to control the replacement tool to: It mates with the worn parts, and The worn part is removed from the roller while it remains positioned on the working surface engagement side of the machine.

9. The method of claim 8, wherein controlling the replacement tool to engage with the worn part comprises: Receive additional sensor data associated with the worn parts; as well as The replacement tool is positioned, at least in part, based on the additional sensor data and using an orientation device movably supported by the load-bearing components of the replacement system, such that the axis of the replacement tool is substantially collinear with the axis of the worn part.

10. The method of claim 9, wherein the additional sensor data is captured by an additional sensor, the additional sensor being carried by the carrier assembly and capable of moving with the replacement tool.

11. The method of claim 9, wherein locating the replacement tool includes The orientation device is used to move the changing tool in a direction substantially parallel to the central longitudinal axis of the roller, and The orientation device is used to rotate the changing tool about an axis that is substantially parallel to the central longitudinal axis of the roller.

12. The method of claim 8, wherein the replacement tool comprises A first component, the first component having: First platform as well as A first arm, movably connected to the first platform, is configured to engage with a base block disposed on the outer surface of the roller and removably holding the wear part; and The second component, the second component having: The second platform is opposite to the first platform. A cup, mounted to the second platform and positioned along the central axis of the replacement tool, is configured to mate with the worn part. The second arm is movably connected to the second platform, and the first component is movable relative to the second component to help remove the worn parts from the roller.

13. A milling machine, comprising: frame; A roller, rotatable relative to the frame and the working surface, wherein the milling machine is disposed on the working surface, and wherein the roller: It is set on the mating side of the working surface of the milling machine, and It is configured to act on the working surface from the working surface engagement side of the milling machine while the milling machine is positioned on the working surface; Multiple wear parts, the multiple wear parts being removably connected to the roller; A sensor, fixedly connected to the frame such that the plurality of worn parts are located within the sensor's field of view; and An electronic controller, comprising a processor and a memory, is configured to: Receive sensor data from the sensor, the sensor data including images of the plurality of worn parts; Using components stored in the memory, the processor identifies wear parts that need replacement from among the plurality of wear parts based on the sensor data, including... The wear duration of each of the plurality of worn parts is determined based on the sensor data, and The multiple worn parts are grouped based on a comparison of wear duration and expected inspection cycle, and one or more worn parts that need to be replaced are identified. The roller is moved to a replacement direction in which the worn part can be accessed by a replacement system operably connected to the controller, the replacement system including a carrier assembly movable relative to the frame and a replacement tool movably supported by the carrier assembly; as well as Control the replacement tool to: It mates with the worn parts, and The worn part is removed from the roller while it remains positioned on the working surface engagement side of the milling machine.

14. The milling machine of claim 13, wherein the controller communicates with a site controller via a network, the controller being configured to provide the sensor data to the site controller via the network.

15. The milling machine of claim 13, further comprising a track connected to the frame and extending substantially parallel to the central longitudinal axis of the roller, wherein the first actuator of the carrying assembly is configured to position the replacement tool on the track, and wherein controlling the replacement tool to engage with the worn part comprises: The first actuator of the carrying assembly moves the changing tool along the track and in a direction substantially parallel to the central longitudinal axis of the roller. The replacement tool is rotated about an axis that extends substantially parallel to the central longitudinal axis of the roller by the second actuator of the bearing assembly, such that the axis of the replacement tool is substantially collinear with the axis of the worn part.

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