System and method for accurately controlling material level of auger bin of paver

Abstract

The invention discloses a paver auger bin material level accurate control system and method.The paver auger bin material level accurate control system comprises a visual sensor, a laser radar sensor, an intelligent processing chip, a control algorithm model, a circuit board, an executing mechanism and a power source module, and the visual sensor is connected with the laser radar sensor and the executing mechanism through lines; the intelligent processing chip is assembled in the circuit board, and the power supply module is connected with the circuit board through a circuit. According to the paver auger bin material level accurate control system and method, comprehensiveness and accuracy of material level information are ensured, it is ensured that the height of the material level is always kept uniform, the phenomenon of material accumulation or vacancy is effectively avoided, the utilization rate and working efficiency of the auger bin are improved, and it is avoided that material distribution and flowing states in the auger bin are different, so that the service life of the auger bin is prolonged. A traditional auger bin material level sensor generally can only detect the material level height of a specific position, so that the whole device cannot be completely controlled.

Description

Technical Field

[0001] The present invention relates to the field of control systems for paving machines, and in particular to a precise control system and method for material level in an auger bin of a paving machine. Background Art

[0002] During the operation of the paver, the auger chamber is a key component for material transportation and distribution. Accurate control of the material level is crucial to ensuring paving quality, improving operating efficiency and extending the service life of the equipment. Existing auger bin material level sensors can usually only detect the material level height at a specific location. These sensors are often fixed at a specific point in the auger bin, such as the bin wall or near the auger shaft, and reflect the material level in the auger bin by measuring the material height at that point. However, since the material distribution in the auger bin is often uneven, especially during the paving operation, the material will continue to flow and change under the push of the auger blades, so the material level measurement at a single location is difficult to accurately reflect the material level status of the entire auger channel; Existing material level sensors also have deficiencies in feedback signal processing. They can usually only be adjusted linearly according to the detected material level height, that is, when the material level height exceeds or falls below the set value, the sensor will output a corresponding signal, and the control unit will linearly adjust the material conveying speed or auger speed of the paver based on these signals. Although this adjustment method is simple and direct, it lacks comprehensive consideration of the material level changes in the entire auger channel, which can easily lead to adjustment lag or over-adjustment, thereby affecting the paving quality and operating efficiency; In summary, the existing auger bin material level sensor technology for pavers has the defects of limited monitoring range and single adjustment method, and cannot realize comprehensive monitoring and intelligent adjustment of the auger channel material level. Summary of the invention

[0003] In response to the shortcomings of the prior art, the present application provides a precise control system and method for the material level in the auger bin of a paver to solve the above-mentioned defects of limited monitoring range and single adjustment method, and the technical problem of being unable to achieve comprehensive monitoring and intelligent adjustment of the material level in the auger channel.

[0004] To achieve the above-mentioned objectives, the present application provides the following technical solutions: a precise control system for the material level of the auger bin of a paver, comprising a visual sensor, a laser radar sensor, an intelligent processing chip, a control algorithm model, a circuit board, an actuator and a power module, wherein the visual sensor is connected to the laser radar sensor and the actuator through lines respectively, the intelligent processing chip is assembled inside the circuit board, and the power module is connected to the circuit board through lines, the visual sensor is installed at the upper end of the paver, and is used to collect image data of the material level of the auger bin; the laser radar sensor is installed in the inner cavity of the paver, and is used to quantify the material level height of the auger bin; the control algorithm model is assembled inside the intelligent processing chip, and is used to cooperate with the visual sensor and the laser radar sensor to dynamically adjust the auger speed; the intelligent processing chip is assembled on the outer surface of the circuit board, and is used to adjust the auger speed according to the control algorithm model; the circuit board is assembled at the lower end of the visual sensor, and is used to assemble the control algorithm model, the intelligent processing chip and the power module; the actuator is assembled in the inner cavity of the paver, and is used to cooperate with the intelligent processing chip to adjust the auger speed.

[0005] Preferably, the visual sensor includes a light source lamp, a camera, an image sensor, a digital-to-analog converter, an image processor and an image memory, and the camera is mounted on the periphery of the ceiling column of the paver. The light source lamp provides lighting for the visual sensor to ensure that the sensor can obtain clear image information. The light source lamp illuminates the interior of the auger bin, so that the visual sensor can clearly obtain the material level data of the auger bin. The camera captures the data information inside the auger bin. The image sensor collects the information captured by the camera. The digital-to-analog converter processes and analyzes the digital image signal, including image compression, display, storage, feature extraction and pattern recognition functions. The image processor and image memory are used to process and analyze the digital image signal, and store the processed image data for subsequent viewing and analysis. At the same time, a communication module is also installed on the outside of the visual sensor for transmitting and outputting the image signal.

[0006] Preferably, the control algorithm model adopts a visual conduction control algorithm and a PID control algorithm, and the control algorithm model is stored in a cloud server. The visual conduction control algorithm uses a visual sensor to obtain an environmental image containing path information, and through image processing technology, it can identify the running path or target object, thereby providing rich environmental information. The PID control algorithm has excellent adaptability and robustness, and can adapt to various types of systems. By cooperating with the visual conduction control algorithm, it can flexibly analyze and process digital image signals.

[0007] Preferably, the laser radar sensor is installed in the inner cavity of the paver, mounted just above the auger channel, and the output end of the laser radar sensor is facing the output port of the auger channel. By being arranged inside the paver, the monitoring accuracy of the internal data of the auger bin is greatly improved, thereby quantifying the material level height of the material-deficient or material-excessive area and improving the overall control effect of the device on the material level in the auger bin.

[0008] Preferably, the laser radar sensor includes a transmitting system, and the outside of the transmitting system is equipped with a receiving system and an information processing system. The transmitting system includes a laser for generating laser pulses to perform data monitoring on the inside of the auger bin. The transmitting system can collect the data collected by the transmitting system through the receiving system, and after the data is centrally processed by the information processing system, it is transmitted to the control algorithm model for collective processing of the data.

[0009] Preferably, the actuator includes a signal receiver and a pneumatic actuator, the input end of the signal receiver is connected to the visual sensor, and the output end of the signal receiver is connected to the pneumatic actuator. The signal receiver can receive the data transmitted by the control algorithm model and transmit the data to the pneumatic actuator, and finally control the interior of the auger bin through the pneumatic actuator.

[0010] Preferably, the power module includes a battery, and the outside of the battery is equipped with a control circuit, a power input terminal and a power output terminal. The power output terminal is connected to the circuit board and the actuator through a line. The battery is used to store energy, and the power supply is controlled by the control line to cooperate with the power output terminal to power the circuit board and the actuator. The power input terminal can connect the external power supply to the battery for power supply.

[0011] Preferably, the intelligent processing chip includes a chip body, a processor core is assembled inside the chip body, and the chip body is assembled outside the circuit board. The chip body is used to support and install the processor core, and the chip body can be assembled outside the circuit board through an installation slot.

[0012] A method for accurately controlling the material level of a auger bin of a paver, using the above-mentioned accurate material level control system of the auger bin of a paver, comprising: S1: Data Collection Install the visual sensor on the periphery of the ceiling column of the paver, start the visual sensor and light source, and the visual sensor begins to collect image data inside the auger chamber; S2: Data collation and transmission The intelligent processing chip receives the image data collected by the visual sensor, analyzes the image data, identifies the material level height of the auger bin, calculates the material level information of the auger bin according to the material profile and distribution, and outputs the result to the actuator; S3: Dynamic adjustment and discharging The actuator performs linear adjustment on the auger pump through the controller according to the received data. The auger pump controls the auger shaft through the auger reducer. Finally, the inside of the auger bin is monitored through the ultrasonic level sensor.

[0013] Preferably, in step S1: data collection, a rotation speed sensor is installed on the outside of the visual sensor, and the visual sensor, the rotation speed sensor and the laser radar sensor cooperate with each other to collect data inside the auger bin at the same time, and the collected data is centrally transmitted to the intelligent processing chip.

[0014] In summary, the present application provides a precise control system and method for the material level of a paver auger bin, which has the following beneficial effects: 1. The precise control system and method for the material level of the auger bin of the paver realizes all-round and high-precision monitoring of the material level of the auger bin through the cooperation of the visual sensor and the laser radar sensor. The visual sensor can obtain the distribution status, color change and texture characteristics of the material in the auger bin in real time, and provide visual information for material level judgment, while the laser radar sensor uses the precise ranging ability of the laser beam to accurately measure the surface height of the material in the auger bin, forming a three-dimensional material level data model, and jointly constructing a three-dimensional monitoring network for the auger bin material level, ensuring the comprehensiveness and accuracy of the material level information; 2. The precise control system and method for the material level of the auger bin of the paver introduces a PID control algorithm to dynamically adjust the auger speed. It can quickly calculate the adjustment amount of the auger speed based on the material level information obtained in real time. By continuously adjusting the auger speed, it ensures that the material level height remains uniform at all times, effectively avoiding the occurrence of material accumulation or vacancy, and improving the utilization rate and work efficiency of the auger bin; 3. The precise control system and method of the auger bin material level of the paver is suitable for a variety of construction conditions, such as fully buried and half-buried complex environments. By integrating the advantages of visual sensors and lidar sensors, as well as the intelligent adjustment capabilities of the PID control algorithm, it successfully realizes the intelligent control of the auger bin material level, avoiding the differences in material distribution and flow conditions in the auger bin. Traditional auger bin material level sensors can usually only detect the material level height at a specific position, which makes it impossible to fully control the entire device. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a schematic diagram of the workflow of the present invention. DETAILED DESCRIPTION

[0016] The following will be combined with the drawings in the embodiments of the present application to clearly and completely describe the technical solutions in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0017] This application provides a technical solution, a precise control system for the material level of the auger bin of a paver, please refer to Figure 1 , including a visual sensor, a lidar sensor, an intelligent processing chip, a control algorithm model, a circuit board, an actuator and a power module. The visual sensor is connected to the lidar sensor and the actuator through lines respectively. The intelligent processing chip is assembled inside the circuit board. The power module is connected to the circuit board through lines. The visual sensor is installed at the upper end of the paver and is used to collect image data of the material level in the auger bin. The lidar sensor is installed in the inner cavity of the paver and is used to quantify the material level height of the auger bin. The control algorithm model is installed in the intelligent processing chip and is used to dynamically adjust the auger speed in cooperation with the visual sensor and the lidar sensor. The intelligent processing chip is installed on the outer surface of the circuit board and is used to adjust the auger speed according to the control algorithm model. The circuit board is installed at the lower end of the visual sensor and is used to assemble the control algorithm model, the intelligent processing chip and the power module. The actuator is installed in the inner cavity of the paver and is used to adjust the auger speed in cooperation with the intelligent processing chip.

[0018] Visual sensors are used to obtain image information of the surrounding environment and perform image processing and analysis. They can also perceive and understand the auger bin, as well as monitor the auger bin. Visual sensors obtain image information through optical systems and imaging elements. Visual sensors have built-in algorithms and tools to preprocess image information, extract features, detect and identify targets, and extract useful information and data. By analyzing and processing image information, visual sensors can perceive environmental states and changes, understand objects, scenes and events, monitor environmental image information, detect abnormal situations and potential risks, and send alarms or control instructions to the system, thereby improving the level of automation and intelligence. Through the information obtained, the system reduces dependence on manual labor, improves work efficiency and product quality, and at the same time provides support for the intelligent upgrade and transformation of the system.

[0019] LiDAR sensors are used for high-precision ranging and three-dimensional modeling, environmental perception and obstacle detection, dynamic tracking and motion analysis. The fusion of LiDAR sensors and vision sensors can significantly improve the redundancy and fault tolerance of the system. By integrating information from multiple sensors, the system can perceive the surrounding environment more comprehensively and accurately and make more reliable decisions.

[0020] Intelligent processing chips, by optimizing chip architecture, adopting manufacturing processes and integrating computing units, can efficiently perform various tasks, including complex calculations and multi-tasking concurrency, thereby improving the overall work efficiency of the equipment. By integrating intelligent algorithms and machine learning technologies, the chip can autonomously learn, analyze and make decisions, making the device behavior more flexible, able to quickly process massive amounts of data, and provide real-time feedback on processing results. It is suitable for application scenarios that require real-time data processing. Intelligent processing chips also improve energy utilization efficiency. By adopting low-power design technology and intelligent power management strategies, the chip effectively reduces energy consumption while ensuring high performance, extending the battery life of the device, and is suitable for application scenarios with high requirements for energy efficiency.

[0021] The control algorithm model characterizes the dynamic characteristics of the system by analyzing the operating mechanism and dynamic changes of the system, providing a basis for the subsequent control strategy design. The control algorithm model proposes control objectives that meet the system requirements, are operational and measurable, and guide the system to develop towards the desired state. The control algorithm model adopts control strategies and optimization methods, takes measures in advance to avoid adverse conditions in the system, and improves the response speed, stability and accuracy of the system. The control algorithm model is adaptable and can automatically adjust the control strategy as the system changes.

[0022] When the system parameters, structure or environment changes, the control algorithm model can identify these changes and adjust the strategy accordingly to ensure that the system remains in the best state. According to the requirements of the control algorithm model, the system structure and parameters are optimized to improve the overall performance of the system. At the same time, the model can provide direction and suggestions for the upgrade and transformation of the system, realizing the automation and intelligence of the system. The system can automatically execute the control strategy without human intervention, and has intelligent decision-making capabilities to make decisions based on real-time conditions. This makes the system run more efficiently, reliably and intelligently. The circuit board is used to support and connect components, electrical connections and signal transmission, protect components and improve integration.

[0023] The visual sensor includes a light source lamp, a camera, an image sensor, a digital-to-analog converter, an image processor and an image memory, and the camera is installed on the periphery of the ceiling column of the paver. The light source lamp provides lighting for the visual sensor to ensure that the sensor can obtain clear image information. The light source lamp illuminates the inside of the auger bin, so that the visual sensor can clearly obtain the material level data of the auger bin. The camera captures the data information inside the auger bin. The image sensor collects the information captured by the camera. The digital-to-analog converter processes and analyzes the digital image signal, including image compression, display, storage, feature extraction and pattern recognition functions. The image processor and image memory are used to process and analyze the digital image signal, and store the processed image data for subsequent viewing and analysis. At the same time, a communication module is also installed on the outside of the visual sensor for transmitting and outputting the image signal.

[0024] The control algorithm model adopts visual conduction control algorithm and PID control algorithm, and the control algorithm model is stored in the cloud server. The visual conduction control algorithm uses visual sensors to obtain environmental images containing path information. Through image processing technology, it can identify the running path or target object, thereby providing rich environmental information. The PID control algorithm has excellent adaptability and robustness, and can adapt to various types of systems. By cooperating with the visual conduction control algorithm, it can flexibly analyze and process digital image signals.

[0025] The laser radar sensor is installed in the inner cavity of the paver, just above the auger channel, and the output end of the laser radar sensor is facing the output port of the auger channel. By being set inside the paver, the monitoring accuracy of the internal data of the auger bin is greatly improved, thereby quantifying the material level height of the material shortage or excess material area and improving the overall control effect of the device on the auger bin material level.

[0026] The laser radar sensor includes a transmitting system, and the outside of the transmitting system is equipped with a receiving system and an information processing system. The transmitting system includes a laser for generating laser pulses to monitor data inside the auger bin. The transmitting system can collect data collected by the transmitting system through the receiving system, and after centrally processing the data through the information processing system, pass it to the control algorithm model for collective data processing.

[0027] The actuator includes a signal receiver and a pneumatic actuator. The input end of the signal receiver is connected to the visual sensor, and the output end of the signal receiver is connected to the pneumatic actuator. The signal receiver can receive the data transmitted by the control algorithm model and transmit the data to the pneumatic actuator, and finally control the interior of the auger bin through the pneumatic actuator.

[0028] The power module includes a battery, and the outside of the battery is equipped with a control circuit, a power input terminal and a power output terminal. The power output terminal is connected to the circuit board and the actuator through a line. The battery is used to store energy, and the power supply is controlled through the control line to cooperate with the power output terminal to power the circuit board and the actuator. The power input terminal can connect the external power supply to the battery for power supply.

[0029] The intelligent processing chip includes a chip body, which is equipped with a processor core inside and is mounted on the outside of the circuit board. The chip body is responsible for performing various complex calculations and processing tasks to ensure that the entire system can run efficiently and accurately. The chip body is provided with a protrusion that matches the circuit board slot, and the circuit board is correspondingly provided with a groove for receiving the protrusion. The chip body can be easily and accurately assembled on the outside of the circuit board, ensuring that the electrical connection between the chip and the circuit board is stable and reliable.

[0030] See also Figure 1 A method for accurately controlling the material level of a auger bin of a paver adopts the above-mentioned accurate material level control system of the auger bin of a paver, comprising: S1: Data Collection Install the visual sensor on the periphery of the ceiling column of the paver, start the visual sensor and light source, and the visual sensor begins to collect image data inside the auger chamber; S2: Data collation and transmission The intelligent processing chip receives the image data collected by the visual sensor, analyzes the image data, identifies the material level height of the auger bin, calculates the material level information of the auger bin according to the material profile and distribution, and outputs the result to the actuator; S3: Dynamic adjustment and discharging The actuator performs linear adjustment on the auger pump through the controller according to the received data. The auger pump controls the auger shaft through the auger reducer. Finally, the inside of the auger bin is monitored through the ultrasonic level sensor.

[0031] Step S1: Data collection. A rotation speed sensor is installed on the outside of the visual sensor. The visual sensor, the rotation speed sensor and the laser radar sensor cooperate with each other to collect data inside the auger bin at the same time, and the collected data is centrally transmitted to the intelligent processing chip.

[0032] The precise control system and method for the material level of the auger bin of the paver realizes all-round and high-precision monitoring of the material level of the auger bin through the cooperation of the visual sensor and the laser radar sensor. The visual sensor can obtain the distribution status, color change and texture characteristics of the material in the auger bin in real time, and provide visual information for material level judgment, while the laser radar sensor uses the precise ranging ability of the laser beam to accurately measure the surface height of the material in the auger bin, forming a three-dimensional material level data model, and jointly constructing a three-dimensional monitoring network for the auger bin material level, ensuring the comprehensiveness and accuracy of the material level information; The PID control algorithm is introduced to dynamically adjust the auger speed. The adjustment amount of the auger speed can be quickly calculated according to the material level information obtained in real time. By continuously adjusting the auger speed, the material level height is ensured to remain uniform, effectively avoiding the occurrence of material accumulation or vacancy, and improving the utilization rate and work efficiency of the auger bin. It is suitable for a variety of construction conditions, such as fully buried and half-buried complex environments. By integrating the advantages of visual sensors and lidar sensors, as well as the intelligent adjustment capabilities of PID control algorithms, it successfully realizes intelligent control of the material level in the auger bin, avoiding the differences in material distribution and flow conditions in the auger bin. Traditional auger bin level sensors can usually only detect the material level height at a specific position, which makes it impossible to fully control the entire device.

[0033] Please refer to the instruction manual Figure 1 First, the preset set value is input into the control algorithm model as the benchmark parameter of the entire control system. The visual sensor is accurately installed and turned on after ensuring that it is in normal working condition. The material distribution and dynamic changes in the bin are captured in real time. The laser radar sensor and the speed sensor work together with the visual sensor to monitor the interior of the auger bin. The laser radar sensor can accurately measure the distance and position information of the material in the bin, while the speed sensor is responsible for monitoring the rotation speed of the auger shaft. The three sensors cooperate with each other to form a full-range monitoring system inside the auger bin. The collected data is transmitted to the intelligent processing chip for processing. The control algorithm model uses the input set value and the real-time data collected by the sensor to accurately control the internal current of the paver through the PID adjustment algorithm, realizing efficient and stable control of the auger pump. The auger shaft is accurately regulated by the auger reducer, and the material level inside the auger bin is detected and controlled to ensure uniform material distribution and stable material level, thereby meeting the high-precision requirements of paving operations.

[0034] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0035] Although the embodiments of the present application have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present application, and that the scope of the present application is defined by the appended claims and their equivalents.

Claims

1. A precise control system for the material level of a paver auger bin, comprising a visual sensor, a laser radar sensor, an intelligent processing chip, a control algorithm model, a circuit board, an actuator and a power module, wherein the visual sensor is connected to the laser radar sensor and the actuator through lines, the intelligent processing chip is assembled inside the circuit board, and the power module is connected to the circuit board through lines, and is characterized in that: The visual sensor is installed at the upper end of the paver and is used to collect image data of the auger bin material level. The laser radar sensor is installed in the inner cavity of the paver and is used to quantify the auger bin material level height. The control algorithm model is assembled inside the intelligent processing chip and is used to cooperate with the visual sensor and the laser radar sensor to dynamically adjust the auger speed. The intelligent processing chip is assembled on the outer surface of the circuit board and is used to adjust the auger speed according to the control algorithm model. The circuit board is assembled at the lower end of the visual sensor and is used to assemble the control algorithm model, the intelligent processing chip and the power module. The actuator is assembled in the inner cavity of the paver and is used to cooperate with the intelligent processing chip to adjust the auger speed.

2. According to claim 1, a precise control system for material level of a paver auger bin is characterized by: The visual sensor comprises a light source lamp, a camera, an image sensor, a digital-to-analog converter, an image processor and an image memory, and the camera is mounted on the periphery of the ceiling column of the paver.

3. According to claim 1, a precise control system for material level of a paver auger bin is characterized by: The control algorithm model adopts a visual conduction control algorithm and a PID control algorithm, and the control algorithm model is stored in a cloud server.

4. The precise control system for material level of the auger bin of a paver according to claim 1, characterized in that: The laser radar sensor is installed in the inner cavity of the paver, installed just above the auger channel, and the output end of the laser radar sensor faces the output port of the auger channel.

5. The precise material level control system for the auger bin of a paver according to claim 1, characterized in that: The laser radar sensor includes a transmitting system, and a receiving system and an information processing system are installed outside the transmitting system.

6. The precise material level control system for the auger bin of a paver according to claim 1, characterized in that: The actuator comprises a signal receiver and a pneumatic actuator. The input end of the signal receiver is connected to the visual sensor, and the output end of the signal receiver is connected to the pneumatic actuator.

7. The precise material level control system for the auger bin of a paver according to claim 1, characterized in that: The power module comprises a battery, and a control circuit, a power input terminal and a power output terminal are mounted on the outside of the battery, and the power output terminal is connected to the circuit board and the actuator through a line.

8. The precise material level control system for the auger bin of a paver according to claim 1, characterized in that: The intelligent processing chip comprises a chip body, a processor core is mounted inside the chip body, and the chip body is mounted outside the circuit board.

9. A method for accurately controlling the material level of a auger bin of a paver, using an accurate material level control system for an auger bin of a paver as described in any one of claims 1 to 8, characterized in that: include: S1: Data Collection Install the visual sensor on the periphery of the ceiling column of the paver, start the visual sensor and light source, and the visual sensor begins to collect image data inside the auger chamber; S2: Data collation and transmission The intelligent processing chip receives the image data collected by the visual sensor, analyzes the image data, identifies the material level height of the auger bin, calculates the material level information of the auger bin according to the material profile and distribution, and outputs the result to the actuator; S3: Dynamic adjustment and discharging The actuator performs linear adjustment on the auger pump through the controller according to the received data. The auger pump controls the auger shaft through the auger reducer. Finally, the inside of the auger bin is monitored through the ultrasonic level sensor.

10. A method for accurately controlling the material level of a auger bin of a paver according to claim 9, characterized in that: The step S1: data collection, the outside of the visual sensor is equipped with a speed sensor, the visual sensor, the speed sensor and the laser radar sensor cooperate with each other to collect data inside the auger bin, and the collected data is centrally transmitted to the intelligent processing chip.

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