System and method for indicating non-ideal state of drum of compactor

Abstract

A system for indicating a non-ideal state of a drum of a compactor includes a sensor coupled to the drum of the compactor that generates a signal indicative of a current amplitude of vibration of the drum. The system also includes a controller including one or more memories and one or more processors. The one or more processors receive a signal from the sensor indicative of a current vibration amplitude of the drum, compare the current vibration amplitude of the drum to a nominal range of vibration amplitudes, determine whether the current vibration amplitude exceeds the nominal range of vibration amplitudes, and if the current vibration amplitude exceeds the nominal range of vibration amplitudes, determine whether the drum is in the nominal range of vibration amplitudes. If so, an output signal is generated. The output signal indicates a non-ideal state of a drum of the compactor.

Description

Technical Field

[0001] This disclosure relates to a compactor, and more particularly to a system for indicating a non-ideal state of the compactor's rollers, and a method for indicating a non-ideal state of the compactor's rollers. Background Technology

[0002] Compactors are typically used to compact materials such as asphalt, sand, aggregates, rock, clay, concrete, or other such materials. A compactor includes one or more rollers that contact the material to be compacted. The rollers may have a smooth outer shell, or they may be rollers with pads. Each roller is equipped with a vibration system that vibrates the corresponding roller at a desired vibration frequency and amplitude to compact the material.

[0003] Due to their interaction with the material being compacted, the compactor's rollers may wear down over time. For example, cracks may propagate in rollers with smooth outer shells, potentially leading to inoperability and / or inefficient compaction. Furthermore, wear on the multiple pads on rollers with pads can result in uneven support and compaction of the compactor. In some instances, material compacted by the compactor may accumulate on the roller shell or on the compactor's pads. This accumulation can increase the roller's mass, which in turn can reduce the roller's vibration amplitude. This reduction in vibration amplitude can decrease the effectiveness of the compaction operation performed by the compactor and may necessitate increasing the number of passes to achieve the desired compaction.

[0004] U.S. Patent Application No. 2020 / 0378554 describes an operating machine including a compactor drum, a controller, and an output device. The compactor drum includes a vibration system comprising at least one bearing and lubricant received by the bearing, the bearing supporting rotation of the vibration system within the compactor drum. The controller is configured to monitor at least one physical characteristic of the vibration system over a specified time period and predict the remaining service life of the lubricant based on the at least one physical characteristic. The output device is configured to generate an output indicating the remaining service life. Summary of the Invention

[0005] In one aspect of this disclosure, a system for indicating a non-ideal state of a compactor drum is provided. The system includes a sensor coupled to the compactor drum. The sensor is configured to generate a signal indicating the current vibration amplitude of the drum. The system also includes a controller. The controller includes one or more memories and one or more processors communicatively coupled to each of the one or more memories and the sensor. The one or more memories are configured to store a nominal range of the drum's vibration amplitude. The one or more processors are configured to receive the signal indicating the current vibration amplitude of the drum from the sensor. The one or more processors are further configured to compare the current vibration amplitude of the drum with the nominal range of vibration amplitude. The one or more processors are further configured to determine whether the current vibration amplitude exceeds the nominal range of vibration amplitude. The one or more processors are configured to generate an output signal if the current vibration amplitude exceeds the nominal range of vibration amplitude. The output signal indicates a non-ideal state of the compactor drum.

[0006] In another aspect of this disclosure, a compactor is provided. The compactor includes a frame. The compactor also includes a roller coupled to the frame. The compactor further includes a system for indicating a non-ideal state of the roller. The system includes a sensor coupled to the roller. The sensor is configured to generate a signal indicating the current vibration amplitude of the roller. The system also includes a controller. The controller includes one or more memories and one or more processors communicatively coupled to each of the one or more memories and the sensor. The one or more memories are configured to store a nominal range of vibration amplitude of the roller. The one or more processors are configured to receive a signal indicating the current vibration amplitude of the roller from the sensor. The one or more processors are further configured to compare the current vibration amplitude with the nominal range of vibration amplitude. The one or more processors are further configured to determine whether the current vibration amplitude exceeds the nominal range of vibration amplitude. The one or more processors are configured to generate an output signal if the current vibration amplitude exceeds the nominal range of vibration amplitude. The output signal indicates a non-ideal state of the compactor's roller.

[0007] In another aspect of this disclosure, a method is provided for indicating a non-ideal state of a compactor drum. The method includes generating a signal indicating the current vibration amplitude of the drum from a sensor coupled to the compactor drum. The method also includes receiving the signal indicating the current vibration amplitude of the drum from the sensor by one or more processors of a controller. The method further includes comparing the current vibration amplitude of the drum with a nominal range of vibration amplitudes by the one or more processors. One or more memories of the controller are configured to store the nominal range of vibration amplitudes of the drum. The method includes determining whether the current vibration amplitude exceeds the nominal range of vibration amplitudes by the one or more processors. The method further includes generating an output signal by the one or more processors if the current vibration amplitude exceeds the nominal range of vibration amplitudes. The method also includes indicating a non-ideal state of the compactor drum based on the generation of the output signal.

[0008] Other features and aspects of this disclosure will be apparent from the following description and accompanying drawings. Attached Figure Description

[0009] Figure 1 This is a schematic perspective view of a compactor according to an example of this disclosure; Figure 2 This is a schematic perspective view of a compactor according to another embodiment of this disclosure; Figure 3 Examples of this disclosure are used for instruction Figure 1 and Figure 2 A schematic perspective view of the system block diagram of a non-ideal state of the compactor's rollers; and Figure 4 Examples of this disclosure are used for instruction Figure 1 and Figure 2 A flowchart of a method for handling the non-ideal state of the compactor drum. Detailed Implementation

[0010] In all the accompanying drawings, the same reference numerals will be used as much as possible to denote the same or similar parts.

[0011] refer to Figure 1 The diagram shows a schematic perspective view of a compactor 100 according to an example of the present disclosure. The compactor 100 may be a soil compactor, asphalt compactor, concrete compactor, landfill compactor, pneumatic roller, tandem vibratory roller, etc. Furthermore, the present disclosure is not limited to the type of compactor 100 and may include any other machinery comprising one or more vibratory rollers or vibratory members whose vibration amplitude can be measured.

[0012] The compactor 100 includes a frame 102. The frame 102 supports multiple components of the compactor 100. The compactor 100 defines a front end 104 and a rear end 106 opposite to the front end 104. The compactor 100 also includes a pair of rear wheels 108.

[0013] The compactor 100 includes a housing 110. The compactor 100 also includes a power source (not shown) disposed within the housing 110. Multiple components of the compactor 100 can be operated by the power source. The power source can be an engine, such as an internal combustion engine, a fuel cell, a battery system, etc., without limiting the scope of this disclosure. The compactor 100 also includes an operator's cab 112. A user can sit in the operator's cab 112 to perform and / or observe the compaction operation.

[0014] The compactor 100 also includes a roller 120 coupled to the frame 102. The roller 120 is disposed at the front end 104 of the compactor 100. In another embodiment, the compactor 100 may include a pair of front wheels disposed at the front end 104 and a roller disposed at the rear end 106 of the compactor 100. In yet another embodiment, the compactor 100 may include a pair of rollers, namely a first roller disposed at the front end 104 of the compactor 100 and a second roller disposed at the rear end 106 of the compactor 100. Furthermore, the roller 120 and the pair of rear wheels 108 together allow the compactor 100 to move on various surfaces.

[0015] exist Figure 1 In the illustrated example, roller 120 includes a roller shell 122 having a smooth outer surface 124. During the compaction operation, the roller shell 122 contacts the material to be compacted.

[0016] In some instances, the compactor 100 also includes a scraper 114. The scraper 114 can remove debris, dirt, or other foreign matter that may accumulate on the roller 120 during compaction operations. In some instances, the scraper 114 may include one or more plates to scrape material from the roller housing 122, without limiting the scope of this disclosure.

[0017] refer to Figure 2 A schematic perspective view of a compactor 200 according to another embodiment of this disclosure is shown. The compactor 200 is substantially similar to the compactor 100 (see [reference]). Figure 1 ( ), where common components are represented by the same numbers. The compactor 200 includes rollers 220. However, in Figure 2 In the illustrated example, the roller 220 of the compactor 200 includes a roller shell 222 having a plurality of pads 226 on its outer surface 224. In other words, instead of the compactor 100, the roller has a smooth outer surface 124 (see [reference needed]). Figure 1 ) roller 120 (see Figure 1The roller 220 includes a plurality of pads 226 that protrude from the outer surface 224 and are fixedly connected to the outer surface.

[0018] Multiple pads 226 can be arranged in any known pattern on the outer surface 224 of the roller 220. Figure 2 In the illustrated example, each pad 226 has a circular shape. In other examples, each pad 226 may have any other shape known in the art, such as a square shape, a rectangular shape, a pentagonal shape, a hexagonal shape, etc., without limiting the scope of this disclosure.

[0019] The compactor 200 also includes a scraper 214. The scraper 214 can remove debris, dirt, or other foreign matter that may accumulate on the roller 220 during compaction operations. In some instances, the scraper 214 may include a brush to remove material from a plurality of pads 226, without limiting the scope of this disclosure. Alternatively, the scraper 214 may include individual scraper sections that may be made of a material such as steel or iron. Individual scraper sections may be fitted between the pads 226.

[0020] Now for reference Figure 3 The diagram shows the indications for compactors 100 and 200 (see [reference]). Figure 1 and Figure 2 A schematic perspective view of a system 300 showing the non-ideal state of rollers 120, 220. Specifically, compactors 100, 200 include a system 300 for indicating the non-ideal state of rollers 120, 220. System 300 can be coupled with a system having a smooth outer surface 124 (see...). Figure 1 The compactor 100 with roller 120 or with pad 226 (see) Figure 2 The compactor 200 is associated with the roller 220.

[0021] System 300 includes sensors 302 connected to rollers 120 and 220 of compactors 100 and 200. Sensors 302 generate signals 304 indicating the current vibration amplitude of rollers 120 and 220. In some instances, sensor 302 may include a displacement sensor. Sensor 302 may include an accelerometer or an optical sensor. In some instances, sensor 302 may be mounted on the vibrating side of a vibration isolation device (not shown) of rollers 120 and 220. Furthermore, system 300 may include a single sensor or a pair of sensors.

[0022] It should be noted that sensor 302 may include any type of sensor 302 and any number of sensors 302 that provide an indication of the current vibration amplitude of rollers 120, 220, and this disclosure is not limited to the type or number of sensors 302. In some instances, when compactors 100, 200 include two rollers, each roller will have a corresponding sensor to provide an indication of the current vibration amplitude of the corresponding roller.

[0023] System 300 also includes a controller 320. Controller 320 includes one or more memories 322. The one or more memories 322 store the nominal range R1 of the vibration amplitude of rollers 120 and 220. The nominal range R1 of vibration amplitude includes the minimum vibration amplitude and the maximum vibration amplitude.

[0024] One or more memories 322 may include any means of storing information, including hard disks, optical disks, floppy disks, ROMs (read-only memories), RAMs (random access memories), PROMs (programmable ROMs), EEPROMs (electrically erasable PROMs), or other computer-readable storage media.

[0025] The controller also includes one or more processors 324. The one or more processors 324 are communicatively coupled to each of the memories in one or more memories 322 and the sensor 302.

[0026] It should be noted that one or more processors 324 may embody a single microprocessor or multiple microprocessors for receiving various input signals and generating output signals. Many commercially available microprocessors can perform the functions of one or more processors 324. One or more processors 324 may also include general-purpose processors, central processing units, application-specific integrated circuits (ASICs), digital signal processors, field-programmable gate arrays (FPGAs), digital circuits, analog circuits, microcontrollers, any other type of processor, or any combination thereof. One or more processors 324 may include one or more components operable to execute computer-executable instructions or computer code, which may be stored and retrieved from one or more memories 322.

[0027] One or more processors 324 receive signals 304 from sensors 302 indicating the current vibration amplitude of rollers 120, 220. The one or more processors 324 compare the current vibration amplitude of rollers 120, 220 with a nominal vibration amplitude range R1. The one or more processors 324 determine whether the current vibration amplitude exceeds the nominal vibration amplitude range R1. Specifically, the processors 324 may determine whether the current vibration amplitude is less than the minimum vibration amplitude or greater than the maximum vibration amplitude.

[0028] If the current vibration amplitude exceeds the nominal range R1, one or more processors 324 further generate an output signal 330. The output signal 330 indicates a non-ideal state of the rollers 120 and 220 of the compactors 100 and 200. Furthermore, if the current vibration amplitude is greater than the nominal range R1, the output signal 330 indicates increased wear on the rollers 120 and 220. Specifically, if the processor 324 determines that the current vibration amplitude of the rollers 120 and 220 is greater than the maximum vibration amplitude, the output signal 330 indicates increased wear on the rollers 120 and 220.

[0029] Furthermore, if the current vibration amplitude is less than the nominal range R1 of the vibration amplitude, the output signal 330 indicates an increase in material accumulation on the rollers 120 and 220. Specifically, if the processor 324 determines that the current vibration amplitude of the rollers 120 and 220 is less than the minimum vibration amplitude, the output signal 330 indicates an increase in material accumulation on the rollers 120 and 220.

[0030] System 300 also includes an output module 340. Output module 340 is communicatively coupled to one or more processors 324. Output module 340 receives output signals 330 from one or more processors 324. Output module 340 generates a notification N1 to indicate to a user a non-ideal state of the rollers 120 and 220 of compactors 100 and 200. The user can be an operator or anyone responsible for compactors 100 and 200.

[0031] In some instances, output module 340 may be a display screen, speaker, smartphone, tablet computer, light, flash, etc. Output module 260 may be located inside operator room 112 (see [link]). Figure 1 and Figure 2 Alternatively, output module 260 may be located outside operator's room 112, enabling notification to a user located outside compactor 100 of non-ideal conditions of rollers 120, 220. Notification N1 may be an audio message, text message, video message, or a combination thereof. For example, if processor 324 determines that the current vibration amplitude of rollers 120, 220 is greater than the maximum vibration amplitude, notification N1 may include a text message regarding increased wear on rollers 120, 220. Alternatively, if processor 324 determines that the current vibration amplitude of rollers 120, 220 is less than the minimum vibration amplitude, notification N1 may include a text message regarding increased material accumulation on rollers 120, 220. In some instances, output module 340 may trigger alarms, buzzers, or light signals to indicate non-ideal conditions of rollers 120, 220, without limiting the scope of this disclosure.

[0032] In some instances, one or more processors 324 receive multiple signals 304 indicating the vibration amplitude of rollers 120, 220 within a predetermined time period. Furthermore, the one or more processors 324 determine whether the vibration amplitude exceeds a nominal range R1 within the predetermined time period. In one instance, the processor 324 may determine the average vibration amplitude of rollers 120, 220 based on the multiple signals 304 received within the predetermined time period. Additionally, the processor 324 may determine whether the average vibration amplitude of rollers 120, 220 exceeds the nominal range R1 within the predetermined time period.

[0033] Furthermore, if the vibration amplitude exceeds the nominal range R1 of the vibration amplitude within a predetermined time period, one or more processors 324 may generate an output signal 330. More specifically, if the current vibration amplitude is less than the minimum vibration amplitude within a predetermined time period, the processor 324 may generate an output signal 330 to indicate an increase in material accumulation on the rollers 120 and 220. Alternatively, if the current vibration amplitude is greater than the maximum vibration amplitude within a predetermined time period, the processor 324 may generate an output signal 330 to indicate increased wear on the rollers 120 and 220.

[0034] It should be understood that a single feature shown or described for one embodiment may be combined with a single feature shown or described for another embodiment. The above embodiments do not limit the scope of this disclosure in any way. Therefore, it should be understood that although some features are shown or described to illustrate the use of this disclosure in the context of the functional paragraphs, such features may be omitted from the scope of this disclosure without departing from the spirit of this disclosure as defined in the appended claims.

[0035] Industrial applicability This disclosure relates to a system 300 for indicating a non-ideal state of rollers 120, 220. System 300 includes a controller 320, which includes one or more processors 324. If the current vibration amplitude exceeds a nominal range R1, the one or more processors 324 generate an output signal 330. System 300 also includes an output module 340 that receives the output signal 330. Output module 340 generates a notification N1 to instruct the user that if the current vibration amplitude is greater than the nominal range R1, wear on rollers 120, 220 has increased, or if the current vibration amplitude is less than the nominal range R1, material accumulation on rollers 120, 220 has increased.

[0036] In this example, processor 324 compares the vibration amplitude to a nominal range R1 over a predetermined time period to indicate non-ideal conditions of compactors 100 and 200. This approach can improve the accuracy of system 300 by eliminating sporadic events that could cause the current vibration amplitude to exceed the nominal range R1.

[0037] System 300 can be used to determine the remaining service life of rollers 120 and 220. System 300 can alert the user that rollers 120 and 220 may require inspection, maintenance, or replacement to maintain the efficiency of compactors 100 and 200. Furthermore, since notification N1 generated by system 300 can be used to determine whether rollers 120 and 220 require maintenance or replacement, system 300 can allow maintenance of rollers 120 and 220 to be scheduled before compactors 100 and 200 become inoperable. In some cases, system 300 can indicate insufficient performance of scrapers 114 and 214 due to, for example, improper setting of scrapers 114 and 214 or defects associated with scrapers 114 and 214, such as wear conditions.

[0038] Furthermore, system 300 can prevent uneven compaction and material damage / waste by generating notification N1 to alert the user to non-ideal conditions of rollers 120 and 220. In some cases, system 300 can reduce maintenance costs, maintenance timelines, and / or downtime of compactors 100 and 200 by alerting the user to any damage to rollers 120 and 220.

[0039] In summary, System 300 has a simple construction and does not include complex components for operation. Furthermore, System 300 can improve the operating time and efficiency of compactors 100 and 200. Additionally, System 300 can be cost-effective, can be retrofitted to existing compactors, and can be easily installed on compactors.

[0040] Figure 4 This is a flowchart of a method 400 for indicating the non-ideal state of the rollers 120 and 220 of compactors 100 and 200. (See reference) Figures 1 to 4 At step 402, the sensor 302 connected to the rollers 120 and 220 of the compactors 100 and 200 generates a signal 304 indicating the current vibration amplitude of the rollers 120 and 220.

[0041] At step 404, one or more processors 324 of the controller 320 receive a signal 304 from the sensor 302 indicating the current vibration amplitude of the rollers 120, 220.

[0042] At step 406, one or more processors 324 compare the current vibration amplitude of rollers 120, 220 with the nominal range R1 of the vibration amplitude. One or more memories 322 of the controller 320 store the nominal range R1 of the vibration amplitude of rollers 120, 220.

[0043] At step 408, one or more processors 324 determine whether the current vibration amplitude exceeds the nominal range R1 of the vibration amplitude.

[0044] At step 410, if the current vibration amplitude exceeds the nominal range R1 of the vibration amplitude, one or more processors 324 generate an output signal 330.

[0045] At step 412, the non-ideal state of the rollers 120 and 220 of the compactors 100 and 200 is indicated based on the generation of the output signal 330.

[0046] Method 400 further includes a step (not shown) in which one or more processors 324 receive multiple signals 304 indicating the vibration amplitude of rollers 120, 220 within a predetermined time period. Method 400 further includes a step (not shown) in which one or more processors 324 determine whether the vibration amplitude exceeds a nominal range R1 of vibration amplitude within the predetermined time period. Method 400 further includes a step (not shown) in which, if the vibration amplitude exceeds the nominal range R1 of vibration amplitude within the predetermined time period, the one or more processors 324 generate an output signal 330.

[0047] Method 400 further includes a step (not shown) in which one or more processors 324 determine a nominal range R1 for the current vibration amplitude that is greater than the vibration amplitude of rollers 120, 220. Method 400 further includes a step (not shown) in which one or more processors 324 generate an output signal 330 based on the current vibration amplitude being greater than the nominal range R1 to indicate increased wear on rollers 120, 220.

[0048] Method 400 further includes a step (not shown) in which one or more processors 324 determine a nominal range R1 of the current vibration amplitude being less than the vibration amplitude of the rollers 120, 220. Method 400 further includes a step (not shown) in which one or more processors 324 generate an output signal 330 based on the current vibration amplitude being less than the nominal range R1 of the vibration amplitude to indicate an increase in material accumulation on the rollers 120, 220.

[0049] The output module 340 is communicatively connected to one or more processors 324. Method 400 further includes a step (not shown) in which the output module 340 receives an output signal 330 from one or more processors 324. Method 400 also includes a step (not shown) in which the output module 340 generates a notification N1 to indicate to a user a non-ideal state of the rollers 120, 220 of the compactors 100, 200.

[0050] It should be noted that steps 402, 404, 406, 408, 410, and 412 of method 400 can be related to... Figure 4The different orders of execution are as described. In addition, various steps 402, 404, 406, 408, 410, and 412 can be executed together.

[0051] Although various aspects of this disclosure have been specifically shown and described with reference to the foregoing embodiments, those skilled in the art will understand that various additional embodiments can be conceived by modifying the disclosed machinery, systems, and methods without departing from the spirit and scope of this disclosure. Such embodiments should be understood to fall within the scope of this disclosure as defined by the claims and any equivalents.

Claims

1. A system for indicating a non-ideal state of a compactor drum, the system comprising: A sensor connected to the roller of the compactor, wherein the sensor is configured to generate a signal indicating the current vibration amplitude of the roller; as well as A controller, comprising one or more memories and one or more processors communicatively coupled to each of the one or more memories and the sensor, wherein the one or more memories are configured to store a nominal range of vibration amplitudes of the roller, and the one or more processors are configured to: Receive a signal from the sensor indicating the current vibration amplitude of the roller; Compare the current vibration amplitude of the roller with the nominal range of the vibration amplitude; Determine whether the current vibration amplitude exceeds the nominal range of the vibration amplitude; as well as If the current vibration amplitude exceeds the nominal range of the vibration amplitude, an output signal is generated, wherein the output signal indicates a non-ideal state of the compactor's drum.

2. The system of claim 1, wherein if the current vibration amplitude is greater than the nominal range of the vibration amplitude, the output signal indicates increased wear of the roller.

3. The system of claim 1, wherein if the current vibration amplitude is less than the nominal range of the vibration amplitude, the output signal indicates an increase in material accumulation on the roller.

4. The system of claim 1, wherein the one or more processors are configured to: Receive multiple signals indicating the vibration amplitude of the roller within a predetermined time period; Determine whether the vibration amplitude exceeds the nominal range of the vibration amplitude within the predetermined time period; and If the vibration amplitude exceeds the nominal range of the vibration amplitude within the predetermined time period, the output signal is generated.

5. The system according to claim 1, wherein the sensor includes a displacement sensor.

6. The system of claim 1, wherein the sensor comprises an accelerometer or an optical sensor.

7. The system of claim 1, further comprising an output module communicatively coupled to the one or more processors, wherein the output module is configured to receive the output signal from the one or more processors, and wherein the output module is configured to generate a notification to indicate to a user a non-ideal state of the compactor's drum.

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