Cold planer truck position sensor system

Abstract

A system for sensing the position of a work machine or loading truck includes an actuator arm suspended downwards from a secondary conveyor of a milling assembly. The actuator arm responds to contact with the truck's tailgate or rear via motion and angle measurements detected using a linear transducer, inclinometer, rotary position sensor, or proximity switch. Based on a predetermined angle measurement, the system triggers an indicator light visible to the truck driver to indicate when to stop or move forward to achieve uniform load distribution. The system can be integrated with software for enhanced control options and requires only a power supply and grounding connection for mounting on the work machine.

Description

Technical Field

[0001] This disclosure relates to a position sensing and guidance system for cold milling machines and job trucks. Background Technology

[0002] Cold milling machines are construction equipment used to remove road surface layers through milling processes. These machines typically include a milling assembly and a conveyor system for transferring the milled material to a transport vehicle. The conveyor system usually includes a secondary conveyor with a delivery end located above the transport vehicle to facilitate material transfer during operation. During milling operations, the cold milling machine moves continuously forward while the transport vehicle (such as a dump truck) is positioned below the conveyor to receive the milled material. Coordination between the cold milling machine and the transport vehicle requires precise positioning to ensure uniform distribution of the milled material within the container of the transport vehicle. Traditional cold milling machine systems employ various methods to coordinate the movement between the milling machine and the transport vehicle, including visual signals, auditory signals, and automated guidance systems.

[0003] U.S. Patent No. 9,562,334 discloses a sensor camera for detecting truck position; however, this patent does not disclose a mechanical actuator arm that physically contacts the truck to detect its position. Therefore, there is a need for an improved cold milling machine truck position sensor system. Summary of the Invention

[0004] This document discloses methods, systems, and apparatus for sensing the position of a cold milling truck or loading truck during material loading operations. The system includes an actuator arm suspended from a secondary conveyor of the milling assembly, configured to accommodate different truck bed sizes and styles. The actuator arm responds to contact with the tailgate or rear of the milling machine using measurements of movement and changing angles detected by a linear transducer, inclinometer, rotary position sensor, proximity switch, or a combination thereof. Based on predetermined angle measurements, the system triggers indicator lights visible to the truck driver to indicate when to stop or move forward to achieve uniform load distribution. The system can be integrated with machine software for enhanced control options and is designed to be universal, requiring only power and ground connections for installation on any brand or model of cold milling machine. This automated guidance system helps reduce operator workload and improve safety by eliminating the need for traditional horn signal communication between the cold milling machine operator and the truck driver.

[0005] In some implementations, the position sensing system is integrated with a secondary conveyor to detect and guide the positioning of the transport vehicle during material delivery operations. An actuator arm extends downward from the conveyor and makes physical contact with the adjacent positioned transport vehicle. The system incorporates sensing technologies through a combination of sensors, such as inclinometers for angle detection, rotary position sensors for movement tracking, proximity sensors for distance measurement, or draw-wire sensors for displacement monitoring. These sensors are protected within a component housing mounted to the conveyor structure. When the actuator arm contacts the transport vehicle and in response to movement of the transport vehicle, the sensors detect this interaction and generate position data. Forward lights mounted on the conveyor side provide visual signals to the vehicle operator. The controller processes the sensor data and activates these lights to guide the operator with movement commands, thereby achieving precise vehicle positioning during material transfer operations.

[0006] In some implementations, the position sensing system integrates sensing technology with a secondary conveyor to detect the position of the transport vehicle during operation. A protective housing is mounted to the conveyor and contains an array of sensor options, such as a tiltmeter to measure angular displacement, a rotary position sensor to track rotational motion, a proximity sensor to detect distance, or a draw-wire sensor to monitor linear displacement. An actuator arm extends downward from the conveyor and physically interacts with the transport vehicle positioned adjacent to the delivery end. When the actuator arm contacts the vehicle, the resulting movement generates sensor data as the vehicle shifts relative to the conveyor structure. The system processes the sensor inputs via a controller that analyzes the movement patterns and position changes detected by the equipped sensors. This sensor integration enables the controller to determine the precise position of the transport vehicle based on the interaction of the actuator arms, thereby providing accurate position monitoring during material transfer operations.

[0007] In some implementations, the positioning of the transport vehicle is monitored during material transfer operations. An actuator arm extends from the conveyor and makes physical contact with the transport vehicle. When contact occurs, sensors such as inclinometers, rotary position sensors, proximity sensors, or pull-wire sensors detect and measure the movement and angular changes of the actuator arm. The system analyzes these measurements to determine the precise position of the transport vehicle relative to the delivery end of the conveyor. Based on this position data, the system activates forward lights mounted on the conveyor to provide clear visual guidance to the vehicle operator, enabling precise positioning adjustments during material transfer. This automated guidance method replaces the traditional horn signal method, simplifying communication between the conveyor operator and the transport vehicle driver while improving operational safety and efficiency. Attached Figure Description

[0008] Figure 1 This is a diagram illustrating an exemplary position sensing system according to some aspects of the present technology.

[0009] Figure 2This is a diagram illustrating an exemplary position sensing system according to some aspects of the present technology.

[0010] Figure 3A This is a diagram illustrating an exemplary position sensing system according to some aspects of the present technology.

[0011] Figure 3B This is a diagram illustrating an exemplary position sensing system according to some aspects of the present technology.

[0012] Figure 3C This is a diagram illustrating an exemplary position sensing system according to some aspects of the present technology.

[0013] Figure 3D This is a diagram illustrating an exemplary position sensing system according to some aspects of the present technology.

[0014] Figure 4A This is a diagram illustrating an exemplary position sensing system according to some aspects of the present technology.

[0015] Figure 4B This is a diagram illustrating an exemplary position sensing system according to some aspects of the present technology.

[0016] Figure 4C This is a diagram illustrating an exemplary position sensing system according to some aspects of the present technology.

[0017] Figure 5A This is a diagram illustrating an exemplary position sensing system according to some aspects of the present technology.

[0018] Figure 5B This is a diagram illustrating an exemplary position sensing system according to some aspects of the present technology.

[0019] Figure 6 This is a flowchart illustrating an exemplary process for a position sensing system according to some aspects of the present technology.

[0020] Figure 7 This is a block diagram illustrating an example of a computer system in which at least some of the operations described herein can be implemented. Detailed Implementation

[0021] Cold milling machines are used in road construction to remove pavement layers by milling, allowing the milled material to be transferred to a transport vehicle using a conveyor system. Milling operations require continuous forward movement while coordinating with the transport vehicle located below the conveyor to receive the milled material. Traditionally, coordination between the cold milling machine operator and the truck driver relies on audible horn signals, where one horn blast indicates a stop and two blasts signal forward movement. This conventional approach presents several challenges. The cold milling machine operator must manage multiple responsibilities simultaneously, including machine speed, tracking, obstacle detection, and communication with ground personnel, while also monitoring truck positioning. When truck drivers are unfamiliar with the signaling system, erroneous communication can occur, potentially leading to safety hazards and reduced machine uptime.

[0022] This document discloses a technology including a truck position sensing system that automates coordination between a cold planer and a transport vehicle. The system includes an actuator arm extending downwards from the (secondary) conveyor of the cold planer and designed to accommodate various truck bed sizes and styles. The actuator arm physically contacts the rear portion (truck bed) of the transport vehicle, positioned adjacent to the delivery end of the conveyor (e.g., below it). The system can combine sensing technologies using a variety of sensor options, including linear transducers, inclinometers, rotary position sensors, and proximity switches. These sensors detect the movement and changing angle measurements of the actuator arm as it interacts with the truck bed. The sensor data is processed by a control system that compares the detected angles with predetermined measurements set by the user.

[0023] Based on this analysis, the system activates an indicator light system mounted on the cold planer and visible to the truck driver. These lights provide visual signals indicating when the driver should stop or move forward, ensuring even load distribution without relying on traditional horn signals. The actuator arm can be configured in multiple mounting positions, including top-mounted and bottom-mounted options relative to the secondary conveyor frame. System components are housed in a protective housing, where wiring harnesses connect the actuators to the indicator lights. The actuator arm itself can be constructed from various materials, such as hydraulic hoses or coated rods, and is designed to prevent damage to the truck tailgate during contact. The mechanism for sensing the position of the actuator arm is adjustable, allowing the use of many different types of sensors. This adjustability of the mechanism enables the disclosed system to be used on a wide variety of different work machines.

[0024] Figure 1 This is a figure illustrating an exemplary position sensing system 108 according to some aspects of the present technology. Figure 1The illustrated environment includes a transport vehicle 104 located near (e.g., below) a secondary conveyor 112 (e.g., below). For example, the container of transport vehicle 104 may be positioned 2 feet, 4 feet, 6 feet, 8 feet, 10 feet, etc., from the cold planer or secondary conveyor 112. The secondary conveyor 112 has a delivery end configured to deliver milling material to transport vehicle 104. In other embodiments, the secondary conveyor 112 may belong to a different working machine than the cold planer.

[0025] The position sensing system 108 includes an actuator arm 116 extending downward from the secondary conveyor 112, allowing it to physically contact a transport vehicle 104 positioned adjacent to the delivery end. The position sensing system 108 includes a sensor system 132 housed within a component housing 120 mounted to the secondary conveyor 112. The sensor system 132 may include multiple sensor types that can work individually or collaboratively to detect movement of the cold planer and / or the transport vehicle 104 and to measure changes in angle when the actuator arm 116 contacts the transport vehicle 104. The sensor system 132 may include a tiltmeter for measuring angular displacement as the actuator arm 116 moves, a rotary position sensor for tracking rotational motion patterns, a proximity sensor for measuring distances between components, and a draw-wire sensor for monitoring linear displacement of the actuator arm 116.

[0026] Signaling system 124 includes a forward light 136 mounted on one side of secondary conveyor 112. The light 136 provides visual movement instructions (including stop and forward commands) to the transport operator based on detected position, replacing conventional horn signals. Position sensing system 108 includes a controller 140 that receives position data 144 from sensor system 132 based on measurements of movement and change angle of the actuator arm. Position data 144 may be digital or analog and may include integrated measurements from one or more sensor types. Controller 140 may include memory and / or analog or digital logic (using...) Figure 7 The exemplary computer system 700 shown is implemented as follows. Controller 140 processes position data 144, for example, by comparing the detected angle with a predetermined measurement, and generates an activation signal 148 to illuminate the appropriate forward turn signal 136 to indicate a truck movement instruction. The activation signal 148 generated by controller 140 triggers the illumination of the forward turn signal 136 based on the processed position data 144, thereby enabling clear visual communication of stop and forward movement instructions to the transport vehicle operator during material transfer operations.

[0027] The actuator arm 116 can be constructed from hydraulic hoses or coated rod material 128 specially designed to prevent damage to the truck tailgate during contact. The actuator arm 116 is adjustable to accommodate different truck bed sizes and styles and can be installed in a centered configuration along the conveyor centerline or in an offset position. The mounting system includes both top-mounting and bottom-mounting options to improve contact with different transport vehicle sizes while maintaining the conveyor's primary material handling function.

[0028] The position sensing system 108 operates using a coordinated sequence of detection, processing, and signaling steps. When the actuator arm 116 contacts the transport vehicle 104 and responds to movement of the transport vehicle, the integrated sensor system 132 detects this interaction through one or more coordinated measurements. The sensor system 132 generates integrated position data through the individual or simultaneous operation of multiple sensor types: a swashplate measures the angular displacement of the arm 116 as it moves, a rotary position sensor tracks rotational motion patterns, a proximity sensor provides distance measurements, and / or a drawwire sensor monitors the linear displacement of the actuator arm 116. The controller 140 receives this position data from the sensor system 132 based on the detected movement and change in angle of the actuator arm 116.

[0029] The controller 140 analyzes measurements by comparing the detected angle with predetermined measurements. This analysis enables precise determination of the position of the transport vehicle relative to the delivery end of the conveyor. Based on this position analysis, the controller 140 processes sensor input and automatically activates the forward indicator lights 136 mounted on the conveyor to provide specific movement instructions to the truck driver. The signaling system 124 illuminates appropriate lights to indicate when the driver should stop or move forward, thereby ensuring uniform load distribution. This automatic guidance replaces traditional horn signals, where lights provide clear and unambiguous visual commands that all operators can easily understand, regardless of their familiarity with conventional signaling methods.

[0030] For example, controller 140 uses the angular displacement range from the inclinometer to indicate when the transport vehicle 104 is properly positioned. A rotational motion threshold from a rotary position sensor can be used to trigger stop and forward commands. A specific proximity sensor distance can be used to determine optimal vehicle positioning. Displacement measurements can be taken using pull-wire sensors corresponding to different loading positions. Controller 140 can use predetermined angular measurements to determine when to activate a specific light.

[0031] As the position of the actuator arm changes in response to truck movement, the position sensing system 108 periodically monitors and updates the light signals in real time, enabling precise vehicle positioning throughout the material transfer operation. This automated sequence significantly reduces operator workload while improving operational safety and efficiency. A wiring harness connects the sensor system 132 to the signaling system 124, with the harness routed along the secondary conveyor 112 between the component housing 120 and the forward lights 136. The entire system 108 requires only a power supply and grounding connection for installation, making it suitable as a universal retrofit solution for any brand or model of cold planer. Furthermore, the position sensing system 108, sensor system 132, signaling system 124, and controller 140, which sense the position of the actuator arm 116, are adjustable, allowing the use of many different types of sensors. The adjustability of the disclosed mechanism enables the system 108 to be used on a wide variety of different work machines, such as different types of cold planers, different types of excavators, work trucks, bulldozers, wheel loaders, etc.

[0032] Figure 2 This is a diagram illustrating an exemplary position sensing system according to some aspects of the present technology. Figure 2 The sensor integration and mounting configuration of a position sensing system are illustrated. The system includes a secondary conveyor 112 with an actuator arm 116 extending downward to contact a transport vehicle positioned in a forward direction 200. The actuator arm 116 is connected to the secondary conveyor 112 via a wiring harness 204 that routes the sensor components and signaling system along the conveyor structure. The mounting system utilizes a magnetic or tool-less mounting element 208, which enables a secure attachment while allowing the system to be folded when not in use. The actuator arm 116 contacts a container on the transport vehicle.

[0033] The sensor system is housed within a component housing 120, which may contain one or more sensing elements that can operate individually or collaboratively. The component housing 120 may be mounted below the secondary conveyor 112 (sometimes referred to as a bottom-mount option). For example, a rotary position sensor 212 tracks the rotational motion pattern of the actuator arm as it responds to contact with the transport vehicle. Multiple proximity sensors 216 can provide distance measurements between the actuator arm 116 and the vehicle component. A drawwire sensor 220 monitors the linear displacement of the actuator arm 116 during operation, while a tiltmeter 224 measures angular displacement as the arm 116 moves in response to contact with the vehicle.

[0034] The housing 120 provides environmental protection for sensitive electronic components while maintaining accessibility for maintenance. The housing 120 is securely mounted to the secondary conveyor 112 and includes connection points for the wiring harness 204 that transmits sensor signals to the controller. The actuator arm 116 can be mounted relative to the secondary conveyor frame in either a top-mount or bottom-mount configuration. The mounting system includes settings for centering and offsetting along the conveyor's centerline to accommodate different operational requirements. This mounting flexibility allows the system to accommodate various cold planer models while maintaining optimal contact with the transport vehicle.

[0035] Figure 2 The sensor integration shown enables position monitoring via one or more measurement methods. For example, the rotary position sensor 212 can operate independently or in conjunction with the proximity sensor 216 to track angular motion and distance changes. A drawwire sensor 220 provides linear displacement data, while the inclinometer 224 monitors angular positioning, creating redundant measurement capabilities to ensure reliable position detection. The wiring harness 204 provides a protected route for sensor signals between the component housing 120 and the system's forward headlight 136, ensuring reliable transmission of movement commands to the transport vehicle operator. The forward headlight 136 can be mounted on the side of the cold planer.

[0036] Magnetic or tool-less mounting hardware 208 facilitates secure attachment during operation and easy removal when the system needs to be folded or repaired. This sophisticated sensor integration and mounting system achieves precise position detection through physical contact rather than visual sensing, providing reliable guidance for carrier positioning during material transfer operations. The system requires only a power supply and grounding connection for installation, making it a universal solution that can be retrofitted to any brand or model of cold planer while maintaining comprehensive position monitoring capabilities.

[0037] Figure 3A This is a diagram illustrating an exemplary position sensing system according to some aspects of the present technology. Figure 3A A bottom view showing the bottom mounting options of the position sensing system illustrates the interaction between the secondary conveyor 112 and the actuator arm 116, and the forward direction 200. The secondary conveyor frame 304 provides the main mounting structure for the position sensing components. The actuator arm 116 extends downward from the secondary conveyor 112 and includes an upper section that connects to the mounting system. The actuator arm is designed to allow physical contact with the transport vehicle while maintaining appropriate clearance during operation.

[0038] The mounting configuration shown illustrates how actuator arm 116 integrates with secondary conveyor frame 304 to maintain positioning relative to the transport vehicle. This arrangement allows the system to adapt to different truck bed sizes and styles while ensuring reliable position detection. The mounting system includes top-mounting and bottom-mounting options, providing installation flexibility while retaining the conveyor's primary material handling function. Actuator arm 116 connects to a sensor system housed within the component housing, which can contain multiple sensor types.

[0039] This mounting arrangement maintains adequate clearance and operational capability while enabling the actuator arm to effectively track the transport vehicle's position during material transfer operations. A forward direction indicator (200°) ensures correct system orientation during installation and operation. The configuration shown allows for position detection while protecting both the sensing system components and the transport vehicle during operation.

[0040] Figure 3B This is a diagram illustrating an exemplary position sensing system according to some aspects of the present technology. Figure 3B A side view is shown of a configuration of the secondary conveyor 112 and two optional actuator arms when engaged with transport vehicle 104. The secondary conveyor frame provides the primary mounting structure for the system components while enabling the delivery of material to the container of transport vehicle 104. In each configuration, the actuator arms extend downward from the secondary conveyor 112 and are in physical contact with the container of transport vehicle 104 positioned adjacent to (e.g., below) the delivery end.

[0041] Figure 3B An optional top mounting option 312 is shown, which connects the actuator arm 116a above the secondary conveyor frame, thereby providing clearance while maintaining effective contact with the transport vehicle 104. In this mounting configuration, the actuator arm 116a can be installed while retaining the conveyor's primary material handling capacity. The material 308 being transferred flows along the secondary conveyor 112, while a position sensing system monitors the position of the transport vehicle through physical contact. Figure 3B An optional bottom mounting option 316 is also shown, in which the actuator arm 116b is mounted at the bottom of the secondary conveyor. Figure 3B The container of the transport vehicle 104 shown is approaching the cold planer, but has not yet made contact with it.

[0042] Figure 3C This is a diagram illustrating an exemplary position sensing system according to some aspects of the present technology. Figure 3CA side view of the position sensing system is shown, illustrating a secondary conveyor 112, an actuator arm 116, and a forward direction 200. The actuator arm 116 engages with the housing of a transport vehicle 104. The secondary conveyor frame provides the primary mounting structure for the system components while enabling material delivery to the transport vehicle 104. The actuator arm 116 extends downward from the secondary conveyor 112 and is in physical contact with the transport vehicle 104, which is positioned adjacent to the delivery end. The system includes a bottom-mounting option that positions the actuator arm 116 below the secondary conveyor frame, providing an alternative mounting configuration while maintaining effective contact with the transport vehicle.

[0043] Figure 3C The illustration shows actuator arm 116 in physical contact with the container of transport carrier 104. Material 308 being transferred flows along secondary conveyor 112, while a position sensing system monitors the position of the transport carrier via physical contact. This illustration demonstrates how the bottom-mounted configuration maintains consistent contact between the actuator arm and the transport carrier while accommodating natural movement and positioning changes that occur during normal milling operations.

[0044] Figure 3D This is a diagram illustrating an exemplary position sensing system according to some aspects of the present technology. Figure 3D A side view of the position sensing system is shown, which illustrates a secondary conveyor 112 and an actuator arm 116. The actuator arm 116 extends downward from the secondary conveyor 112 and is in physical contact with a transport vehicle 104 positioned adjacent to the delivery end. Figure 3D Compared to Figure 3C This shows the actuator arm 116 being pushed back further.

[0045] Figure 4A This is a diagram illustrating an exemplary position sensing system according to some aspects of the present technology. Figure 4A The top view shows a top mounting option for the position sensing system, illustrating the integration of one or more sensor types within a component housing 120 mounted to the secondary conveyor 112. The system operates in the forward direction 200 and includes an actuator arm 116 extending downwards to physically contact the transport vehicle. The component housing 120 contains a complex array of sensors that can work individually or in combination to provide comprehensive position monitoring capabilities.

[0046] Rotary position sensor 212 tracks the rotational motion pattern of the actuator arm as it responds to contact with the transport carrier. A drawwire sensor 220 monitors linear displacement during operation, providing accurate measurements of positional changes and movement of the actuator arm relative to the secondary conveyor 112. Inclinometer 224 measures angular displacement as arm 116 moves in response to carrier contact, enabling accurate detection of changing angle measurements during operation. This sensor integration demonstrates how multiple measurement techniques can work together to provide redundant position monitoring capabilities through a combination of different sensor types.

[0047] Rotary position sensor 212 can work in conjunction with draw-wire sensor 220 to track both rotational motion and linear displacement, while inclinometer 224 provides additional angular position data. This combination of sensors allows the system to maintain accurate position detection through physical contact rather than visual sensing methods. Component housing 120 provides environmental protection for these sensitive electronic components while maintaining accessibility for maintenance and repair. Housing 120 is securely mounted to the secondary conveyor frame and includes connection points for the wiring harness used to deliver sensor signals to the control system.

[0048] Figure 4B This is a diagram illustrating an exemplary position sensing system according to some aspects of the present technology. Figure 4B A bottom view showing the top mounting option of the position sensing system, which shows the actuator arm 116 mounted to the secondary conveyor frame 304.

[0049] Figure 4C This is a diagram illustrating an exemplary position sensing system according to some aspects of the present technology. Figure 4C A side view showing the top mounting options for the position sensing system illustrates the secondary conveyor frame 304, actuator arm 116, and forward direction 200. The actuator arm 116 can be positioned relative to the secondary conveyor in either a centered or offset configuration. In a centered actuator arm configuration, the arm 116 is positioned exactly in line with the centerline of the secondary conveyor, providing balanced contact with the transport vehicle during operation. In contrast, in an offset configuration, the actuator arm 116 can be positioned to one side of the secondary conveyor, providing installation flexibility while maintaining effective truck position sensing capabilities.

[0050] The component housing 120 may contain multiple sensor types, individually or working together, to provide comprehensive position monitoring regardless of the selected actuator arm configuration. A draw-wire sensor 220 monitors linear displacement during operation, providing accurate measurements of positional changes of the actuator arm relative to the secondary conveyor frame 304. These measuring components are strategically positioned to maintain accurate readings regardless of whether the actuator arm 116 is in a centered or offset configuration. A rotary position sensor 212 and a tiltmeter 224 may work individually or together to provide comprehensive position monitoring in both centered and offset actuator arm configurations. For example, the rotary position sensor 212 tracks rotational motion patterns when the actuator arm 116 responds to contact with the transport vehicle, providing accurate measurements of the arm's angular displacement relative to the secondary conveyor frame 304. The tiltmeter 224 measures changing angle measurements as the actuator arm 116 moves in response to vehicle contact, working in conjunction with the rotary position sensor 212 to provide redundant angular position data. This dual-sensor approach enables the system to maintain accurate position detection through physical contact rather than visual sensing. Both sensors are protected within a component housing 120 mounted to the secondary conveyor frame 304, and their outputs are processed by a controller that analyzes the combined motion patterns and angular variations.

[0051] In some implementations, sensor integration enables precise determination of the transport vehicle's positioning by monitoring rotational motion via rotary position sensor 212 alone and angular displacement via inclinometer 224, either individually or simultaneously. This sophisticated sensor combination provides reliable position detection regardless of whether the actuator arm 116 is mounted in a centered or offset configuration. The system processes the sensor inputs via a controller that analyzes movement patterns and positional changes detected by the equipped sensors in both mounting configurations. Sensor integration enables precise position detection via physical contact rather than visual sensing methods, providing reliable guidance for transport vehicle positioning during material transfer operations. In both centered and offset configurations, the system achieves consistent physical contact between the actuator arm 116 and the transport vehicle while accommodating natural movement and positioning changes that occur during normal milling operations. This mounting flexibility allows the system to accommodate various cold planer models while maintaining optimal contact with the transport vehicle.

[0052] Figure 5A This is a diagram illustrating an exemplary position sensing system according to some aspects of the present technology. Figure 5A A top view of the position sensing system relative to the secondary conveyor 112 is shown. Figure 5A An optional centering configuration is shown, which includes positioning the actuator arm 116a along the centerline of the secondary conveyor 112 to provide balanced contact with the transport vehicle during operation.

[0053] Figure 5A An optional offset configuration is also shown, in which actuator arm 116 is offset to one side of the secondary conveyor 112. Both alternative configurations enable improved positioning for standard material transfer operations while maintaining consistent contact with the transport vehicle. A centrally located installation provides symmetrical loading and uniform force distribution during operation. In parallel, the offset configuration positions actuator arm 116b to one side of the secondary conveyor's centerline, providing installation flexibility for situations where a centrally located installation is not optimal. This offset arrangement maintains full position sensing capability while accommodating different machine layouts and operational requirements. Both configurations can be integrated with a sensor system housed within the component housing. Figure 5A The diagram illustrates how two installation options maintain adequate clearance and operational capability while enabling effective transport vehicle position tracking during material transfer operations.

[0054] Figure 5B This is a diagram illustrating an exemplary position sensing system according to some aspects of the present technology. Figure 5B A side view of the position sensing system is shown, illustrating a secondary conveyor with two optional actuator arm configurations. In the centered configuration, actuator arm 116a is positioned directly beneath the secondary conveyor, while in the offset configuration, actuator arm 116b is in an offset mounting position. The centered configuration positions actuator arm 116a along the centerline of the secondary conveyor, thereby providing balanced contact with the transport vehicle during material transfer operations. This configuration enables positioning while maintaining consistent contact between actuator arm 116a and the transport vehicle. The centered mounting configuration can include a complete sensor array, including inclinometers, rotary position sensors, proximity sensors, and / or pull-wire sensors 220, to provide comprehensive position monitoring.

[0055] The offset configuration positions the actuator arm 116b to one side of the secondary conveyor's centerline, providing installation flexibility for situations where centering is not optimal. This configuration maintains full position sensing capability through sensor integration while adapting to different machine layouts and operational requirements. In each configuration, the actuator arm is connected to a sensor system housed within a component housing mounted to the secondary conveyor. Figure 5B The side view shows how the two mounting options maintain proper clearance and operational capability while enabling effective transport vehicle position tracking during material transfer operations.

[0056] Figure 6 This is a flowchart illustrating an exemplary process for a position sensing system according to some aspects of the present technology. In some embodiments, the process is performed by reference to... Figure 1 The position sensing system 108 is shown and described in more detail. In other embodiments, see reference to... Figure 7The computer system 700 is shown and described in more detail as performing some or all of the steps of the process. Similarly, implementations may include different and / or additional steps, or these steps may be performed in a different order.

[0057] At 604, the actuator arm is positioned such that it extends downward from the conveyor system. This actuator arm is specifically designed to make physical contact with the transport vehicle positioned at the delivery end of the adjacent conveyor. The arm's positioning accommodates various truck bed sizes and styles, allowing for versatile application in different transport vehicle configurations. The system can be installed in a centered configuration along the conveyor's centerline or in an offset position, with both top-mounting and bottom-mounting options available to optimize contact with the transport vehicle. The actuator arm incorporates protective materials, such as hydraulic hoses or coated rod structures, to prevent damage to the transport vehicle during contact while ensuring reliable position detection.

[0058] At point 608, when the actuator arm contacts the transport vehicle, the integrated sensor system detects and measures the resulting movement and angular changes. Sensing techniques can combine one or more sensor types, including inclinometers for angle detection, rotary position sensors for movement tracking, proximity sensors for distance measurement, and / or draw-wire sensors for displacement monitoring. In some embodiments, one or more sensor types work together to detect and measure the movement of the actuator arm when it contacts the transport vehicle. For example, an inclinometer tracks angular displacement as the arm moves, while a rotary position sensor monitors rotational motion patterns.

[0059] Proximity sensors provide distance measurements, while draw-wire sensors track the linear displacement of the actuator arm. These sensors are housed within a protective housing mounted to the conveyor and work together to provide comprehensive motion data via mechanical contact rather than visual sensing. This combination of different sensor types enables redundant measurement capabilities, ensuring reliable and accurate position detection as the actuator arm responds to contact with the transport vehicle. As described above, these sensors are protected within a housing mounted to the conveyor and work together to provide comprehensive motion data as the actuator arm responds to contact with the transport vehicle. The system captures measurements of changing angles and movement patterns that occur as the actuator arm interacts with the vehicle, enabling precise position detection via mechanical contact rather than visual or projected energy sensing.

[0060] In some implementations, the actuator arm includes adjustable features that allow it to adapt to different truck bed sizes and styles during operation. The system is designed to allow for flexible positioning through various mounting configurations, including top-mount and bottom-mount options, to optimize contact with different transport vehicle sizes. The actuator arm may be constructed from materials such as hydraulic hoses or coated rods, providing adaptable contact surfaces while preventing damage to different truck configurations. This adjustability ensures that the system can maintain effective position sensing across a range of transport vehicle sizes, while preserving the integrity of both the sensing system and the vehicle it monitors.

[0061] In some implementations, different mounting configurations can be used to mount the actuator arm onto the conveyor structure. In a top mounting configuration, the actuator arm is positioned above the secondary conveyor frame, while in a bottom mounting option it is placed below. Both mounting arrangements are designed to maintain proper contact with the transport vehicle while preserving the conveyor's primary material handling function. The mounting system includes features for secure attachment and component protection, where the actuator arm's position is optimized for effective truck position detection, regardless of the chosen mounting configuration. This flexibility in mounting options allows the system to adapt to different cold planer models and operating requirements while maintaining reliable position sensing capabilities.

[0062] In some implementations, the actuator arm can be mounted in either a centered or offset configuration. In the centered configuration, the actuator arm is aligned with the centerline of the secondary conveyor, while in the offset configuration, the actuator arm is positioned to one side of the conveyor's centerline. Both configurations maintain the arm's ability to contact and track the position of the transport vehicle, while accommodating different operational requirements. The centered arrangement provides balanced contact with the truck bed directly beneath the conveyor, while the offset position offers installation flexibility when centered mounting may not be optimal. The system's sensors and control mechanisms function effectively in either configuration, ensuring reliable position detection regardless of whether the actuator arm is centered or offset relative to the conveyor structure.

[0063] At point 612, sensor data is processed to calculate the position of the transport vehicle relative to the delivery end of the conveyor. Multiple sensor inputs work together—inclinometers provide angular displacement data, rotary position sensors track motion patterns, proximity sensors measure distance, or draw-wire sensors monitor linear displacement. The control system analyzes these varying measurements to accurately determine the position of the transport vehicle, enabling precise tracking of its position as it moves beneath the conveyor. Compared to traditional vision-based systems, this mechanical sensing method offers more direct and reliable position detection because it relies on physical contact measurements rather than projected energy sensing.

[0064] At point 616, based on the determined position of the transport vehicle, forward lights mounted on the side of the conveyor are activated to provide visual guidance to the vehicle operator. These lights indicate specific movement commands, such as stop and forward commands, replacing the traditional horn signal method. The signaling system processes position data from sensors and automatically illuminates the appropriate lights to guide the truck driver to optimal positioning for uniform material distribution. This automated visual guidance system eliminates potential communication errors that can occur with conventional audible signals, especially when working with operators who may be unfamiliar with specific horn signal patterns.

[0065] In some implementations, the signaling system utilizes forward-facing lights mounted on the sides of the conveyor to provide visual guidance to the transport operator. When activated based on position data from sensors, these lights illuminate in a specific pattern to convey movement commands, such as stop and forward commands, replacing traditional horn signaling methods. These lights are connected to the sensor system via protective wiring harnesses that run along the conveyor from the component housing to the light mounting locations. This visual signaling method provides clear and unambiguous movement commands that all operators can easily understand, regardless of their familiarity with conventional horn signaling patterns.

[0066] Industrial applicability The disclosed equipment and systems have broad applicability in a variety of building and infrastructure development scenarios where material loading and transport operations are critical. The disclosed position sensing system demonstrates versatility beyond cold planer applications through its universal design requiring only power and grounding connections for installation. The system's basic approach, using an actuator arm with integrated sensors to detect carrier positioning, can be applied to any machine requiring coordinated material transfer operations. The system's flexible installation configurations, including top-mount and bottom-mount options, as well as centered and offset arrangements, allow it to adapt to various equipment layouts and operational requirements.

[0067] Protective design features, such as coated actuator arms and enclosed component housings, ensure durability in diverse building environments. This automated guidance system replaces traditional manual signaling methods with reliable mechanical sensing, making it valuable in any building scenario where precise positioning between material handling equipment and transport vehicles is critical. The system's ability to provide clear visual guidance while reducing operator workload makes it particularly beneficial for large-scale material transfer operations across a wide range of building and infrastructure development applications.

[0068] The benefits and advantages of the embodiments described herein include the system's universal design, requiring only power and grounding connections for installation on any brand or model of cold planer. The disclosed system can be implemented as a standalone retrofit solution or integrated with machine software for enhanced control options. The disclosed automated guidance system significantly reduces operator workload by eliminating the need for continuous monitoring and manual signaling, while improving overall safety and operational efficiency. The truck position sensing system offers several significant advantages over conventional methods of coordinating movement between the cold planer operator and the transport vehicle. By replacing conventional horn signal communication with an automated mechanical sensing system, this invention reduces the workload of cold planer operators who previously had to manage multiple responsibilities simultaneously, including machine speed, tracking, obstacle detection, and ground personnel communication.

[0069] The system's actuator arm and integrated sensors provide reliable position detection through physical contact with the transport vehicle, eliminating potential communication errors associated with traditional audible signals, especially when working with new truck drivers unfamiliar with specific signal patterns. Protective component housings and a durable actuator arm structure, using materials such as hydraulic hoses or coated rods, ensure system longevity while preventing damage to the transport vehicle during contact. Multiple sensor types working in tandem—including inclinometers, rotary position sensors, proximity sensors, and pull-wire sensors—provide redundant position monitoring capabilities, enhancing system reliability and accuracy. A forward-facing light system provides clear visual guidance to the transport vehicle operator, improving operational safety by reducing the risk of miscommunication and potential accidents. Furthermore, the system's flexibility in installation configurations, including both centered and offset positions, as well as top and bottom mounting options, allows for optimal installation based on specific equipment requirements and operating conditions. This integrated approach of position sensing and automated guidance improves overall safety, increases machine uptime, and enhances operational efficiency during milling operations.

[0070] Figure 7 This is a block diagram illustrating an example of a computer system 700 in which at least some of the operations described herein can be implemented. Components of the computer system 700 can be used to implement... Figure 1 The position sensing system 108 shown is shown.

[0071] As shown in the figure, a computer system 700 may include: one or more processors 702, main memory 706, non-volatile memory 710, network interface device 712, video display device 718, input / output device 720, control device 722 (e.g., keyboard and pointing device), drive unit 724 including storage medium 726, and signal generation device 720 communicatively connected to bus 716. Bus 716 represents one or more physical buses and / or point-to-point connections connected via appropriate bridges, adapters, or controllers. For simplicity, Figure 7 Various common components (e.g., cache memory) have been omitted. Instead, computer system 700 is intended to illustrate hardware devices on which components shown or described with respect to the examples in the accompanying drawings, as well as any other components described in this specification, may be implemented.

[0072] Computer system 700 can take any suitable physical form. For example, computer system 700 can share with server computers, personal computers (PCs), tablet computers, mobile phones, game consoles, music players, wearable electronic devices, network-connected (“smart”) devices (e.g., televisions or home assistant devices), AR / VR systems (e.g., head-mounted displays), or any electronic device capable of executing a set of instructions specifying actions(s) to be taken by computer system 700. In some embodiments, computer system 700 can be an embedded computer system, a system-on-a-chip (SOC), a single-board computer system (SBC), or a distributed system such as a computer system grid, or include one or more cloud components in one or more networks. Where appropriate, one or more computer systems 700 can perform operations in real-time, near real-time, or in batch mode.

[0073] Network interface device 712 enables computer system 700 to mediate data in network 714 with external entities using any communication protocol supported by computer system 700 and entities outside computer system 700. Examples of network interface device 712 include network adapter cards, wireless network interface cards, routers, access points, wireless routers, switches, multilayer switches, protocol converters, gateways, bridges, bridging routers, hubs, digital media receivers and / or repeaters, and all wireless elements described herein.

[0074] Memory (e.g., main memory 706, non-volatile memory 710, machine-readable medium 726) can be local, remote, or distributed. Although shown as a single medium, machine-readable medium 726 can include multiple media (e.g., centralized / distributed databases and / or associated caches and servers) storing one or more sets of instructions 728. Machine-readable (storage) medium 726 can include any medium capable of storing, encoding, or carrying a set of instructions for execution by computer system 700. Machine-readable medium 726 can be non-transitory or include non-transitory means. In this context, non-transitory storage medium can include tangible means, meaning that the means has a concrete physical form, but the means can change its physical state. Thus, for example, non-transitory means that the means remains tangible despite the change in state.

[0075] Although implementations have been described in the context of a full-featured computing device, various examples can be distributed as program products in various forms. Examples of machine-readable storage media, machine-readable media, or computer-readable media include recordable media (such as volatile and non-volatile memory device 710, removable flash memory, hard disk drive, optical disk) and transmission media (such as digital and analog communication links).

[0076] Typically, routines executed to implement the examples herein can be implemented as part of an operating system or a particular application, component, program, object, module, or sequence of instructions (collectively, a “computer program”). A computer program typically includes one or more instructions (e.g., instructions 704, 708, 728) set at different times in various memories and storage devices within a computing device(s). When read and executed by processor 702, the instructions(s) cause computer system 700 to perform operations to execute elements relating to various aspects of this disclosure.

Claims

1. A position sensing system, comprising: A secondary conveyor, the secondary conveyor having a delivery end configured to deliver materials to a transport vehicle; The actuator arm extends downward from the secondary conveyor. The actuator arm is configured to contact the transport vehicle; The sensor system is connected to the actuator arm. The sensor system includes at least one of a tiltmeter, a rotational position sensor, a proximity sensor, or a pull-wire sensor, configured to detect the movement and change angle measurements of the actuator arm when the actuator arm contacts the transport vehicle; A component housing, which is mounted to the secondary conveyor and contains the sensor system; A signaling system, the signaling system including a forward light mounted on one side of the secondary conveyor; as well as Controller, the controller is configured to: Position data is received from the sensor system based on the movement and change angle measurements of the actuator arm, and The forward lights are activated based on the location data to signal the operator of the transport vehicle a movement instruction.

2. The position sensing system of claim 1, wherein the actuator arm includes at least one of a hydraulic hose or a coating rod configured to prevent damage to the transport vehicle.

3. The position sensing system of claim 1, wherein the actuator arm is adjustable to fit the size of the transport vehicle.

4. The position sensing system of claim 1, wherein the actuator arm is mounted on the secondary conveyor in either a top-mounted configuration or a bottom-mounted configuration.

5. The position sensing system of claim 1, wherein the actuator arm is positioned relative to the secondary conveyor in either a centered or offset configuration.

6. The position sensing system of claim 1, wherein the signaling system is configured to instruct the transport vehicle operator to at least one of a stop instruction or a forward movement instruction.

7. The position sensing system of claim 1, comprising a wiring harness connecting the sensor system to the signaling system. The wiring harness is routed along the secondary conveyor between the component housing and the front light.

8. A position sensing system for a conveyor assembly, comprising: A secondary conveyor with a delivery end; Sensor assembly, the sensor assembly comprising: The component housing installed on the secondary conveyor; and At least one of the following: Incisor located within the housing of the component; A rotational position sensor located within the housing of the component; A proximity sensor located within the housing of the component; or A pull-wire sensor positioned within the housing of the component; An actuator arm extends downward from the secondary conveyor and is operatively coupled to the sensor assembly. The actuator arm is configured to: Contact is positioned near the delivery end of the transport vehicle, and Responding to the contact, it moves relative to the secondary conveyor; and A controller configured to determine the position of the transport vehicle based on input from at least one of the inclinometer, the rotational position sensor, the proximity sensor, or the pull-wire sensor.

9. The position sensing system of claim 8, wherein the actuator arm is mounted in a centered configuration relative to the secondary conveyor, the centered configuration positioning the actuator arm along the centerline of the secondary conveyor.

10. The position sensing system of claim 8, wherein the actuator arm is mounted in an offset configuration relative to the secondary conveyor, the offset configuration positioning the actuator arm off-center from the centerline of the secondary conveyor.

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