Material unloading system for vehicles

Abstract

A material unloading system for vehicles, including: i) a rectangular frame 101 with a first and a second section designed to be installed on a carrier of a loading vehicle, wherein several motorized C-shaped clamps 102 are arranged with the frame to obtain a grip on the edges of the carrier near the frame in order to secure the frame to the carrier in a secure manner; ii) an interactive touch display 103 associated with the system and connected to the vehicle's control panel, which a user accesses to provide input specifications regarding a user-requested unloading process, whereupon an integrated microcontroller connected to the vehicle's ECU detects the inactive / active status of the vehicle; iii) an artificial intelligence-based imaging unit 104, installed on the frame and paired with a processor to capture and process multiple images of the frame, or to determine the position of raw material previously placed on the first section; iv) a plate 105 arranged vertically at the proximal end of the first section by means of a hydraulic actuator operated by an integrated microcontroller to extend / retract the plate 105 to exert a movement on the plate 105 which exerts a sliding movement on the received material to transport the user-specific material towards the second section; and v) a conveyor belt 106 arranged on the second section which receives the transferred material, wherein an ultrasonic sensor is embedded on the frame to detect the presence of the transferred material, on the basis of which the microcontroller actuates the conveyor belt 106 to move the material in order to release the material onto a floor surface, thereby assisting the user in unloading the user-specific quantity of material.

Description

FIELD OF THE INVENTION

[0001] The present invention relates to a material unloading system for vehicles that determines the position of the picked-up raw material with respect to the transfer of the user-defined material for discharge on the ground surface. BACKGROUND OF THE INVENTION

[0002] A vehicle is a machine designed to transport people or goods from one place to another. Vehicles come in various shapes and sizes, such as cars, trucks, buses, etc. The material unloading system typically refers to a specialized facility designed for the efficient unloading of materials. Traditionally, material unloading involves the use of specialized vehicles designed for the transport and unloading of various types of materials, commonly used for the transport and unloading of earth, gravel, sand, or construction debris. Dump trucks have a hydraulic lifting mechanism that allows the vehicle's bed to be raised and tilted to discharge the material.

[0003] Conventionally, these methods are useful. However, traditional methods have their limitations. Conventional methods are expensive, time-consuming, and require manual effort, and they are unable to determine the position of the accommodated raw material with respect to the transfer of the user-specific material. Therefore, it is necessary to develop a system that determines the position of the accommodated raw material with respect to the transfer of the user-specific material for distribution on the soil surface.

[0004] US20050053451A1 discloses a loading and unloading system for loading articles into and unloading articles from at least one storage area having an open end and interior side walls. The loading and unloading system comprises a powered cart for carrying articles, having two sides, the distance therebetween defining a cart width, the cart also having front and rear ends defining a longitudinal axis therebetween. The cart comprises a rigid main frame movable along the longitudinal axis over the floor, a powered article transport device mounted on the cart frame for transporting the articles on the cart, and a number of lateral guide members mounted on the frame and projecting laterally beyond the frame on both sides of the cart.Furthermore, the present system comprises a pair of elongated guide gates, each gate defining an inner end having a fastener for movably securing the inner end of the gate at a distance from the open end of the storage area and an outer free end opposite the inner end, the guide gates being movable between a retracted position in which the outer free ends of the gates are intended to clear the side walls of the storage area and an extended position in which the outer free ends of the gates are each intended to engage a corresponding side wall of the storage area.The carriage's side guide elements are designed to continuously engage the guide gates as the carriage moves between the gates in the extended position toward and away from the open end of the storage area, guiding the carriage toward and away from the storage area during loading and unloading of items. While the US'451 is capable of loading and unloading vehicles, the system is unable to determine the position of the picked-up raw material.

[0005] US11659788B2 discloses an automatic material unloading system that may include a fill model and a discharge controller. The fill model is a model of a fill characteristic of a container as a function of variables including material discharge times, material discharge rates, and material discharge locations. The discharge controller is to (a) determine a current model-based fill characteristic of the container using the dynamic fill model and (b) output control signals to adjust at least a material discharge time, a material discharge rate, and a material discharge location based on the current model-based fill characteristic of the container. Although US'788 is capable of loading and unloading the container, the system lacks the ability to deposit the material on a floor surface to discharge the user-specified amount of material.

[0006] Conventionally, many material unloading devices have been developed. However, they have their own limitations, as they are unable to determine the position of the loaded raw material with respect to the transfer of the material specified by the user.

[0007] To overcome the above-mentioned drawbacks, there is a need in the art to develop a system capable of determining the position of the picked-up raw material with respect to the transfer of the user-specific material and dispensing the material onto a floor surface. SUBJECT OF THE INVENTION

[0008] The main object of the present invention is to overcome the disadvantages of the prior art.

[0009] An object of the present invention is to develop a system capable of distributing the material on a floor surface to unload the amount of material specified by the user.

[0010] Another object of the present invention is to develop a system capable of determining the position of the picked-up raw material with respect to the transfer of the user-defined material.

[0011] Another object of the present invention is to develop a system that is reliable.

[0012] The foregoing and other objects, features and advantages of the present invention will become readily apparent upon closer examination of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings. SUMMARY OF THE INVENTION

[0013] The present invention relates to a material unloading system for vehicles that determines the position of the picked-up raw material with respect to the transfer of the user-specific material for dispensing the material on the ground surface.

[0014] According to one embodiment of the present invention, a material unloading system for vehicles comprises a rectangular frame having a first and a second section, a plurality of motorized C-shaped clamps arranged with the frame to obtain a grip on the edges of the carrier, an interactive touch display connected to the system to provide input specifications regarding a user-desired unloading operation, a built-in microcontroller connected to the vehicle's ECU detects the inactive / active status of the vehicle, an artificial intelligence-based imaging unit installed on the frame to determine the position of a raw material, a platen arranged vertically at the proximal end of the first section by means of a hydraulic actuator to set the platen in motion.

[0015] According to another embodiment of the present invention, the proposed system further comprises an ultrasonic sensor embedded in the frame to detect the presence of the transferred material, a conveyor belt arranged on the second section to dispense the material onto a floor surface, a vertical linear actuator integrated below the frame to extend / retract to raise the frame, a weight sensor is embedded in the second section to monitor the weight of the transferred material, a plurality of motorized flaps are arranged at the proximal end of the second section to enable dispensing from the carrier of the vehicle, a proximity sensor is embedded in the frame to detect the presence of obstacles, a battery is configured with the system to provide a continuous power supply.

[0016] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations are possible which would fall within the scope of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] These and other features, aspects and advantages of the present invention will be better understood from the following description, the appended claims and the accompanying drawings, in which: Fig. Figure 1 shows an isometric view of a vehicle material unloading system. Fig. Figure 2 shows an isometric view of a motorized valve positioned at the proximal end. DETAILED DESCRIPTION OF THE INVENTION

[0018] The following description contains the preferred best mode for carrying out an embodiment of the present invention. It will be apparent from this description of the invention that the invention is not limited to the illustrated embodiments, but that the invention also includes a variety of modifications and embodiments therein. Therefore, the present description should be considered as illustrative and not restrictive. While the invention is susceptible to various modifications and alternative constructions, it should be understood that there is no intention to limit the invention to the specific form disclosed, but on the contrary, the invention is intended to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0019] In any embodiment described herein, the open-ended terms “comprising,” “comprises,” and the like (which are synonymous with “including,” “with,” and “characterized by”) may be replaced by the respective partially closed terms “consisting essentially of,” “consists essentially of,” and the like, or the respective closed terms “consisting of,” “consists of,” and the like.

[0020] As used herein, the singular forms “a,” “an,” and “the” refer to both the singular and the plural, unless expressly intended to refer to the singular only.

[0021] The present invention relates to a material unloading system for vehicles capable of determining the position of the picked-up raw material with respect to the transfer of the user-specific material in order to discharge the material onto the ground surface.

[0022] With reference to Fig. 1 and Fig.2, an isometric view of a vehicle material unloading system and an isometric view of a motorized flap disposed at the proximal end are shown, each consisting of a rectangular frame 101 having a first and a second section, a plurality of motorized C-shaped clamps 102 disposed with the frame, an interactive touch display 103 connected to the system, an artificial intelligence-based imaging unit 104 installed on the frame, a platen 105 vertically disposed at the proximal end of the first section, a conveyor belt 106 disposed at the second section, and a plurality of motorized flaps 201 disposed at the proximal end.

[0023] The disclosed system consists of a rectangular frame 101 having a first and a second part, which are designed to be installed on the carrier of a loading vehicle. A plurality of motorized C-shaped clamps 102 are arranged with the frame to grip the edges of the carrier near the frame to securely attach the frame to the carrier. There are two to four motorized C-shaped clamps 102 in number. The number of motorized C-shaped clamps 102 is between six and eight. The motorized C-shaped clamps 102 are a fastening device used to firmly hold or secure the carrier to prevent movement or separation of the frame. The clamp consists of a pair of curved motorized C-shaped clamps 102 connected to a motor to grip the carrier near the frame.The motor is actuated by the microcontroller to open / close the motorized C-shaped clamps 102 to fix the frame to the carrier in a secured manner.

[0024] After the frame is securely mounted on the carrier, a system-connected interactive touch display 103, which is connected to the vehicle's control panel, is accessed by a user to provide input specifications regarding the user's desired unloading process. The touch-sensitive interactive display panel 103 mentioned here is typically an LCD (liquid crystal display) screen that presents the output in a visible form. The screen is equipped with touch-sensitive technology that allows the user to interact directly with the display using their fingers. A touch controller IC (integrated circuit) is responsible for processing the analog signals generated when the user enters details regarding the unloading process.The touch controller is usually connected to a microcontroller integrated into the system via various interfaces such as SPI (Serial Peripheral Interface) or I2C (Inter-Integrated Circuit) to allow the user to enter input data for the desired discharge process.

[0025] Upon providing the input specifications, the microcontroller connected to the vehicle's ECU detects the inactive / active status of the vehicle. An ECU (Electronic Control Unit) is essentially a small computer that controls the actuators in a car. The ECU controls everything in the engine, including wheel speed, braking power, ignition timing, idle speed, and the air-fuel mixture. The ECU continuously monitors the airflow entering the engine using sensors such as the mass airflow (MAF) sensor or the manifold absolute pressure (MAP) sensor. By accurately assessing the intake air, the ECU adjusts the fuel injection amounts to maintain the ideal air-fuel mixture for optimal combustion and performance and detects the vehicle's inactive / active status.

[0026] After detecting the inactive / active status of the vehicle, an artificial intelligence-based imaging unit 104 installed on the frame captures and processes multiple images of the frame to determine the position of a raw material previously placed on the first section. The artificial intelligence-based imaging unit 104 includes a camera lens and a processor. The 360-degree rotatable camera captures multiple images of the frame, and the processor then performs a sequence of steps including preprocessing, feature extraction, and segmentation.

[0027] During preprocessing, unwanted data such as noise and background are removed, and the image is converted into a format recommended for feature extraction. The features, such as the pixel intensities of the foreground image, are extracted and passed on to classification to determine the position of the raw material occurring on the first section.

[0028] After determining the position of the raw material stored on the first section, a plate 105, arranged vertically at the proximal end of the first section, is actuated by a hydraulic actuator controlled by a built-in microcontroller to extend / retract the plate 105 and generate movement. The hydraulic actuator is driven by a hydraulic unit consisting of a hydraulic cylinder, a hydraulic compressor, a hydraulic valve, and a piston, which work together to allow the actuator to extend / retract as required. The microcontroller actuates the valve to allow hydraulic fluid to flow from the compressor into the cylinder. The hydraulic fluid builds pressure against the piston, causing the piston to push and extend.The piston is connected to plate 105, and due to the applied pressure, plate 105 extends. Similarly, the microcontroller retracts plate 105 by closing the valve, resulting in the retraction of the piston. The microcontroller controls the extension / retraction of plate 105 to impart movement to plate 105, with a view to transferring the user-defined material toward the second section.

[0029] When the material specified by the user is transported to the second section, a weight sensor embedded in the second section monitors the weight of the transported material. The weight sensor consists of a coiled diaphragm and a sensor module. The size of the diaphragm changes based on the weight of the material in the second portion, which is detected by the sensor module. The sensor module records the weight of the material, and based on the changes in the diaphragm's size, the recorded data is transmitted to the microcontroller. If the transferred material corresponds to the amount specified by the user, the microcontroller controls the actuation of the hydraulic actuator.

[0030] Additionally, an ultrasonic sensor embedded in the frame detects the presence of the transferred material. The ultrasonic sensor works by emitting ultrasonic waves and then measuring the time it takes these waves to bounce back after hitting the surface of the transferred material. The ultrasonic sensor consists of two main parts: a transmitter and a receiver that detects the presence of the transferred material. The transmitter sends a short ultrasonic pulse toward the surface of the transferred material, which travels through the air at the speed of sound and is reflected back to the transmitter as an echo once the pulse hits the transferred material.The transmitter then detects the echo reflected from the surface of the material to be transmitted, and the sensor performs calculations based on the time interval between the transmitted signal and the reception of the echo to determine the presence of the material to be transmitted.

[0031] To detect the presence of the transferred material, a plurality of motorized flaps 201 located at the proximal end of the second section are actuated by a microcontroller to open / close to enable dispensing from the vehicle's carrier. The number of motorized flaps 201 is between four and six. The motorized flap typically operates with an electric motor or actuator to control the movement of the flap and automatically open or close with the aid of the motor to enable dispensing from the vehicle's carrier.

[0032] When the material can be removed from the vehicle's carrier, a proximity sensor embedded in the frame detects the presence of obstacles on the surface as the material is removed from the carrier, after which the microcontroller controls the actuation of the conveyor belt 106. The proximity sensor used here is preferably an ultrasonic proximity sensor, which uses ultrasonic waves to detect the presence of obstacles on the surface. The ultrasonic proximity sensor typically emits ultrasonic waves toward the obstacles on the surface, with the ultrasonic waves hitting the obstacles and bouncing back to the sensor's receiver. The receiver of the ultrasonic proximity sensor is sensitive to the emitted ultrasonic waves and listens for the reflected waves.When the emitted ultrasonic waves are received by the receiver, the proximity sensor sends the data to the microcontroller, which processes and analyzes the acquired data to detect the presence of obstacles on the surface while the material is dispensed from the carrier.

[0033] When the microcontroller detects the presence of obstructions on the surface, it actuates the conveyor belt 106 to shift the material and deposit it on a floor surface, assisting the user in unloading the user-specified amount of material. The conveyor belt 106 consists of a belt stretched in a tight loop over two or more pulleys, and one of the pulleys is connected to a drive motor coupled to the microcontroller. When actuated, the drive motor rotates the pulley, which in turn causes the primary conveyor belt 106 to rotate as well, resulting in the unloading of the user-specified amount of material.

[0034] In case the user wants to apply a large amount of material to the floor surface at once, the microcontroller actuates a vertical linear actuator integrated beneath the frame to extend / retract the frame, lifting and tilting the frame so that the material can be applied to the surface. The vertical linear actuator consists of a motor, a lead screw, and a nut. When activated by the microcontroller, the motor generates a rotational force, which is then converted into linear motion by the interaction between the lead screw and the nut. The lead screw, driven by the motor, rotates and causes the nut to move along its thread. This motion pushes or pulls the connected chain, exerting pressure on the desired rivet.As the actuator extends, it exerts the necessary force to remove the rivet, effectively releasing the chain to extend / retract the frame to lift and tilt it to allow the material to be distributed over the surface.

[0035] Finally, a battery is installed in the system which is connected to the microcontroller that supplies power to all the electrically operated components that require a certain amount of electrical energy to perform their functions and operation in an efficient manner. The battery used here is usually a dry battery, which is made of lithium-ion material and provides the system with a long lifespan along with an efficient direct current that helps all the components to function properly and efficiently. Since the system is battery operated, it does not require any electrical voltage for its operation. The presence of a battery leads to the mobility of the system, meaning the user can move the system from one place to another as per their requirement.

[0036] The present invention works best in the following manner, where the proposed system consists of a rectangular frame 101 having a first and second part. Several motorized C-shaped clamps 102 acquire the grip of the edges of the support, near the frame for attaching the frame to the support in a secured manner. After attaching the frame to the support in a secured manner, the interactive touch display 103 is called by the user to provide input specifications regarding the user-desired unloading process, based on which a built-in microcontroller detects the inactive / active status of the vehicle. Furthermore, the artificial intelligence-based imaging unit 104 acquires and processes several images of the frame to determine the position of the raw material housed on the first part.After determining the position of the raw material, the plate 105 is actuated by the hydraulic actuator by a built-in microcontroller to extend / retract the plate and enable movement 105 to transport the user-specified material toward the second section. Furthermore, the ultrasonic sensor detects the presence of the transferred material, whereupon the microcontroller actuates the conveyor belt 106 to set the material in motion to dispense the material onto a floor surface, thereby assisting the user in unloading the user-specified amount of material. In the event that the user wishes to dispense a large amount of material onto the floor surface at once, the microcontroller actuates the vertical linear actuator to extend / retract the frame to tilt the frame to dispense the material onto the surface.

[0037] Although the scope of the invention has been described herein with limited reference to specific embodiments, this description is not intended to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the invention, will become apparent to those skilled in the art upon reference to the description of the invention. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] US 20050053451A1

[0004] US 11659788B2

[0005]

Claims

[1] A material unloading system for vehicles, comprising: i) a rectangular frame 101 having a first and a second section, designed to be installed on a carrier of a loading vehicle, wherein a plurality of motorized C-shaped clamps 102 are arranged with the frame to obtain a grip of the edges of the carrier near the frame in order to fix the frame on the carrier in a secured manner; ii) an interactive touch display 103 associated with the system and connected to the vehicle's control panel, which is accessed by a user to provide input specifications regarding a user-desired discharge operation, whereupon a built-in microcontroller connected to the vehicle's ECU detects the inactive / active status of the vehicle; iii) an artificial intelligence-based imaging unit 104 installed on the frame and paired with a processor to capture and process multiple images of the frame or to determine the position of a raw material previously placed on the first section; iv) a plate 105 arranged vertically at the proximal end of the first section by means of a hydraulic actuator operated by a built-in microcontroller to extend / retract the plate 105 to impart a movement to the plate 105 which imparts a sliding movement to the received material to transport the user-specific material towards the second section; and v) a conveyor belt 106 disposed on the second section, which receives the transferred material, wherein an ultrasonic sensor is embedded on the frame to detect the presence of the transferred material, based on which the microcontroller actuates the conveyor belt 106 to displace the material to discharge the material onto a floor surface, thereby assisting the user in unloading the user-specified amount of material. [2] The system of claim 1, wherein, in the event that the user wishes to dispense a large amount of the material at once onto the floor surface, the microcontroller actuates a vertical linear actuator integrated beneath the frame to extend / retract the frame with a view to tilting the frame to dispense the material onto the surface. [3] The system of claim 1, wherein a weight sensor is embedded in the second section to monitor the weight of the transferred material, and wherein the microcontroller controls the actuation of the hydraulic actuator when the transferred material corresponds to the amount specified by the user. [4] The system of claim 1, wherein a plurality of motorized flaps 201 are disposed at the proximal end of the second portion, which are actuated by the microcontroller to be opened / closed to enable dispensing from the carrier of the vehicle. [5] The system of claim 1, wherein a proximity sensor is embedded in the frame to detect the presence of obstacles on the surface while the material is being dispensed from the carrier, whereupon the microcontroller controls the actuation of the conveyor belt 106. [6] The system of claim 1, wherein a battery is configured with the system to provide a continuous power supply to electronically operated components connected to the system.

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