Compactor having control system for estimating remaining compaction work

Abstract

A compactor has a chassis and a work tool. The compactor has a power source configured to propel the work tool over the work surface. The compactor has a sensor that determines a compaction value of the work surface and a control system, including a processor. The processor receives a target compaction value and a current compaction value from the sensor. The processor determines a required number of compaction passes of the compactor over the work surface to achieve the target compaction value based at least on the current compaction value and the target compaction value. The processor displays, on a display screen, an indicator representative of the required number of compaction passes. In addition, the processor adjusts an operating parameter of the compactor such that an amount of remaining power in the power source is sufficient for the compactor to complete the required number of compaction passes.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to a compactor machine and more particularly to a compactor machine having a control system for estimating a remaining amount of compaction work.BACKGROUND

[0002] A compactor or machine equipped with a vibratory roller is used to compact loose materials such as asphalt, soil, gravel, or other earthen materials to create a densified and more rigid mass or surface. For example, soil compactors are used to compact soil at construction sites and on landscaping projects to produce a foundation on which other structures such as a building or an asphalt road may be built. Most soil compactors include one or more rotatable roller drums that are rolled over the soil or other work surface to compress the material underneath. In addition to using the weight of the roller drum to provide compressive forces for compacting the material, some compactors also induce a vibratory force on the surface to achieve compaction. For example, one or more eccentrically located weights in the roller drums may be rotated at a predetermined rotational speed to impart an additional impulse load on the material beneath the roller drums to further improve the ability of the compactor to compact the material.

[0003] Conventionally, the number of passes of the compactor over a work surface required to compact material under the work surface to a desired level of compaction, and selection of other machine operating conditions are determined based upon operator judgment and perception. This requires substantial operator training and preparation time, and these approaches can potentially introduce human error, producing inconsistent compaction levels of the work surface. Modern compactors are provided with sensors that can determine the compaction level of the work surface as the compactor rolls over the work surface. The determined compaction level can be displayed to an operator of the machine. U.S. Patent Publication No. 2023 / 0220645 to Doy et al., published on Jul. 13, 2023, and discloses such a system. Although displaying the current compaction level allows an operator to know how far the current compaction level of a work surface is from the target compaction level, the operator still lacks information that can be used to determine a remaining amount of time or fuel required to achieve the target compaction level.

[0004] The compactor of the present disclosure solves one or more of the problems set forth above and / or other problems of the prior art.SUMMARY

[0005] In one aspect, the present disclosure is directed to a compactor. The compactor may include a chassis and at least one work tool configured to support the chassis on a work surface. The compactor may also include a power source configured to propel the at least one work tool over the work surface. The compactor may further include at least one sensor configured to determine a compaction value associated with the work surface. The compactor may also include a control system, including a processor. The processor may be configured to receive a target compaction value for the work surface and a current compaction value from the at least one sensor. The processor may also be configured to determine a required number of compaction passes of the compactor travelling over the work surface to achieve the target compaction value based at least on the current compaction value and the target compaction value. Further, the processor may be configured to display, on a display screen, an indicator representative of the required number of compaction passes. In addition, the processor may be configured to adjust at least one operating parameter of the compactor such that an amount of remaining power in the power source is sufficient for the compactor to complete the required number of compaction passes.

[0006] In another aspect, the present disclosure is directed to a control system for a compactor including a chassis, at least one work tool configured to support the chassis on a work surface, and a power source configured to propel the at least one work tool over the work surface. The control system may include a memory storing instructions, and a processor configured to execute the instructions. The processor may be configured to receive a target compaction value for the work surface and a current compaction value from at least one sensor configured to determine a compaction value associated with the work surface. The processor may also be configured to determine a required number of compaction passes of the compactor over the work surface to achieve the target compaction value based at least on the current compaction value and the target compaction value. Further, the processor may be configured to display, on a display screen, an indicator representative of the required number of compaction passes. The processor may also be configured to adjust at least one operating parameter of the compactor such that an amount of remaining power in the power source is sufficient for the compactor to complete the required number of compaction passes.

[0007] In another aspect, the present disclosure is directed to a method of controlling operations of a compactor including a chassis, at least one work tool configured to support the chassis on a work surface, a power source configured to propel the at least one work tool over the work surface. The method may include receiving, using a processor, a target compaction value for the work surface and a current compaction value from at least one sensor configured to determine a compaction value associated with the work surface. The method may also include determining, using the processor, a required number of compaction passes of the compactor over the work surface to achieve the target compaction value based at least on the current compaction value and the target compaction value. Further, the method may include displaying, on a display screen, an indicator representative of the required number of compaction passes. The method may include determining, using the processor, a first amount of power available from the power source to propel the compactor. The method may include determining, using the processor, a second amount of power required to propel the compactor for the required number of compaction passes. In addition, the method may include adjusting, using the processor, at least one operating parameter of the compactor when the first amount of power is less than the second amount of power.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is an illustration of an exemplary compactor machine;

[0009] FIG. 2 is an illustration of an exemplary control system for the compactor of FIG. 1; and

[0010] FIG. 3 is an illustration of an exemplary method performed by the control system of FIG. 2.DETAILED DESCRIPTION

[0011] FIG. 1 illustrates an exemplary machine that may be a construction machine such as compactor 10. Compactor 10 may include chassis 12, which may extend from front end 14 to rear end 16. Chassis 12 may have any shape (e.g., rectangular, triangular, square, etc.). Chassis 12 may be supported by work tool 18 adjacent to front end 14 and by one or more wheels 20 adjacent to rear end 16. In some embodiments, compactor 10 may be supported by work tools 18 adjacent to both front end 14 and rear end 16. Some or all work tools 18 and wheels 20 may be steerable, allowing compactor 10 to be turned towards the right or left during a forward or rearward motion of compactor 10. In one exemplary embodiment as illustrated in FIG. 1, work tool 18 may include roller 22. In some embodiments, roller 22 may be a vibratory roller configured to compact work surface 30 on which compactor 10 operates. Work tool 18 (including roller 22) and wheels 20 may help support chassis 12 and work tool 18 on work surface 30.

[0012] Roller 22 may include vibratory mechanism 24 that may be disposed inside an interior volume of roller 22. Vibratory mechanism 24 may include one or more weights or masses disposed at a position off-center from the respective central axis around which roller 22 rotates. As roller 22 travels on work surface 30, the off-center or eccentric positions of the masses induce oscillatory or vibrational forces to roller 22, which imparts those forces to work surface 30. The weights may be eccentrically positioned with respect to the respective central axis of rotation of roller 22 and the weights may be movable relative to each other (e.g., about the respective central axis) to produce varying degrees of imbalance during rotation of roller 22. The amplitude of the vibrations produced by such an arrangement of eccentric rotating weights may be varied by modifying and / or otherwise controlling the position of the eccentric weights with respect to each other, thereby varying the average distribution of mass (i.e., the centroid) with respect to the axis of rotation of the weights. Vibration amplitude in such a system may increase as the centroid moves away from the axis of rotation of the weights and may decrease toward zero as the centroid moves toward the axis of rotation. Varying the rotational speed of the weights about their common axis may change the frequency of the vibrations produced by such an arrangement of rotating eccentric weights.

[0013] Compactor 10 may include a power source 26, which may be configured to provide motive power to work tool 18 (including roller 22), wheels 20, and / or one or more machine components (e.g., motors, pumps, actuators, etc.) associated with compactor 10. In some exemplary embodiments, power source 26 may include a combustion engine, which may be attached to chassis 12. The combustion engine may be any suitable type of internal combustion engine, such as a gasoline, diesel, natural gas, or hybrid-powered engine. In some exemplary embodiments, power source 26 may include one or more batteries or other devices configured to deliver electrical power to an electric engine, including, for example, one or more motors that may in turn propel work tool 18 and wheels 20 on work surface 30.

[0014] Compactor 10 may include operator platform 28, which may be attached to chassis 12. In some exemplary embodiments, operator platform 28 may be in the form of an open-air platform that may or may not include a canopy. In other exemplary embodiments, operator platform 28 may be in the form of a partially or fully enclosed cabin as illustrated in, for example, FIG. 1. Operator platform 28 may include one or more controls, which may be used by an operator to operate and / or control one or more operating parameters of compactor 10. The controls may include, for example, one or more input devices, which may take the form of buttons, switches, sliders, levers, wheels, touch screens, or other input / output or interface devices. Compactor 10 may also include one or more display screens (not shown in FIG. 1) that may be configured to display one or more operational parameters or other information to an operator of compactor 10. In some embodiments, one or more of the display screens may also serve as input devices, for example, in the form of a touch-sensitive screen for receiving inputs from an operator of compactor 10. Compactor 10 may also include compactor control system 40 that may be configured to control operations of one or more components of compactor 10. Compactor 10 may be configured to be operated autonomously, semi-autonomously, or manually. When operating semi-autonomously or manually, compactor 10 may be operated by remote control and / or by an operator physically located within operator platform 28 of compactor 10.

[0015] Compactor 10 may be configured to make one or more forward passes over work surface 30, one or more reverse passes over work surface 30, or a combination of both forward and reverse passes. During a forward pass, compactor 10 may travel over work surface 30 in a forward direction, for example, in a direction from rear end 16 towards front end 14. Similarly, during a reverse pass, compactor 10 may travel over work surface 30 in a rearward direction, for example, in a direction from front end 14 towards rear end 16. Compactor 10 may be required to make more than one forward and / or reverse pass over work surface 30 to achieve a desired amount of compaction of the material under work surface 30.

[0016] FIG. 2 illustrates an exemplary embodiment of work site control system 50 that may include compactor control system 40, back-end control system 60, and network 70. Compactor control system 40 may include, for example, one or more control modules 80, input devices 82, display devices 84, alert devices 86, and / or sensors 88. Control module 80 may include one or more processors 90, memory devices 92, and / or communications interfaces 94. Control module 80 may be configured to control operations of one or more of work tools 18, wheels 20, power source 26, input devices 82, display devices 84, actuators, and / or other components of compactor 10. Processor 90 may embody a single or multiple microprocessors, digital signal processors (DSPs), application-specific integrated circuit devices (ASICs), etc. Numerous commercially available microprocessors can be configured to perform the functions of processor 90. Various other known circuits may be associated with processor 90, including power supply circuitry, signal-conditioning circuitry, and communication circuitry.

[0017] The one or more memory devices 92 may store, for example, one or more control routines, instructions, and / or data for determining a remaining amount of compactor work for compactor 10, and / or for controlling one or more other machine characteristics or operating parameters of compactor 10. Memory device 92 may embody non-transitory computer-readable media, for example, Random Access Memory (RAM) devices, NOR or NAND flash memory devices, and Read Only Memory (ROM) devices, CD-ROMs, hard disks, floppy drives, optical media, solid state storage media, etc. Control module 80 may receive one or more input signals from the one or more input devices 82 and may execute the routines or instructions stored in the one or more memory devices 92 to generate and deliver one or more command signals to one or more of power source 26, roller 22, wheel 20, actuators, and / or other components of compactor 10.

[0018] Communications interface 94 may allow software, instructions, and / or data to be transferred between an off-board work site control system 50 and control module 80 via network 70. Examples of communications interface 94 may include a network interface (e.g., a wireless network card), a communications port, a PCMCIA slot and card, a cellular network card, a global positioning system (GPS) transceiver, etc. Communications interface 94 may transfer software and / or data in the form of signals, which may be electronic, electromagnetic, optical, or other signals capable of being transmitted and received by communications interface 94. Communications interface 94 may transmit or receive these signals using a radio frequency (“RF”) link, Bluetooth link, satellite links, and / or other wireless communications channels. In some exemplary embodiments, data or instructions may be received via communications interface 94 and may be stored in memory device 92. In some exemplary embodiments, one or more control signals for controlling one or more of work tool 18, wheel 20, power source 26, actuators, and / or other components of compactor 10 may be received by control module 80 from back-end control system 60 via network 70 and communications interface 94.

[0019] One or more input devices 82 may be located in operator platform 28. Input devices 82 may include one or more of joysticks, keyboards, knobs, levers, pedals, touch screens, or other input devices known in the art. An operator of compactor 10 may use one or more input devices 82 to provide one or more inputs, which may be received by control module 80. For example, the one or more input device 82 may be configured to receive a target compaction value from an operator. Input devices 82 may also be used to operate compactor 10 and may be used to manually control one or more of work tool 18, wheel 20, power source 26, and / or other components of compactor 10. For example, input devices 82 may be used to control a ground speed of compactor 10, a rotational speed of work tool 18 or wheel 20, rotational speed and or angular separation between weights located within roller 22, and / or to steer compactor 10.

[0020] One or more display devices 84 may be associated with control module 80 and may be configured to display data or information in cooperation with processor 90. Display device 84 may be a cathode ray tube (CRT) monitor, a liquid crystal display (LCD), a light emitting diode (LED) display, a touchscreen display, or any other kind of display device known in the art. In some embodiments, display device 84, when configured as a touchscreen display, may be configured to receive one or more inputs from an operator that may be the same as or different from the one or more inputs received via input devices 82.

[0021] Alert device 86 may be associated with control module 80 and may be configured to generate an audible, a visual, or an audio-visual alert based on instructions received from processor 90. Alert device 86 may be a separate device or may be incorporated in display device 84 to provide audio-visual alerts to an operator of compactor 10. In some embodiments, alert device 86 may additionally or alternatively be incorporated in the one or more input devices 82 to provide haptic feedback to an operator of compactor 10.

[0022] Sensors 88 may include for example, compaction sensor 100, ground speed sensor 102, position sensor 104, fuel sensor 106, battery sensor 108, vibration sensor 110, and / or other sensors configured to monitor operational parameters associated with compactor 10. The term sensor should be interpreted to include one or more sensors and related components that may be associated with compactor 10 and that may cooperate to sense various functions, operations, and operating characteristics of compactor 10 and / or aspects of the environment in which compactor 10 is operating. Some operating characteristics or operational parameters of compactor 10 may include, for example, engine speed, engine torque, engine temperature, pressures and flow rates in various hydraulic or other fluid flow components of compactor 10, and / or other conditions or characteristics of one or more components of compactor 10.

[0023] Compaction sensor 100 may be configured to measure a compaction value of work surface 30 being traversed by compactor 10. In some embodiments, compaction sensor 100 may be configured to measure machine drive power (MDP) that correlates compaction with rolling resistance to provide an indication of a stiffness of work surface 30. In some embodiments, compaction sensor 100 may be configured to measure compaction meter value (CMV) that provides an indication of material stiffness of the material under work surface 30. In some embodiments, compaction sensor 100 may be configured to determine one or both of the MDP and / or CMV values associated with a compaction value of work surface 30.

[0024] Ground speed sensor 102 may be associated with one or more of work tool 18 and / or wheels 20 and may be configured to measure a speed (e.g., feet per second, miles per hour, etc.) at which work tool 18 and / or wheels 20 may be propelled over work surface 30. Ground speed sensor 102 may be configured to generate one or more signals indicative of a ground speed of one or more of work tool 18 and / or wheels 20, and may send the one or more signals to control module 80. Control module 80 may be configured to additionally or alternatively determine a ground speed of compactor 10 in other ways, for example, using GPS sensors, inertial sensors, flow rate or pressure of hydraulic fluid in hydraulic motors associated with one or more of work tool 18 and / or wheels 20, or electric current flowing through electric motors associated with one or more of work tool 18 and / or wheels 20.

[0025] Position sensor 104 may be configured to determine a position of compactor 10 on a work site. For example, position sensor 104 may embody a Global Positioning System (GPS) device, an Inertial Reference Unit (IRU), a local tracking system, or any other position sensor capable of determining positional information of compactor 10 relative to a reference location or a reference coordinate system. In other embodiments, position sensor 104 together with processor 90 may be configured to determine the position of compactor 10 based on triangulation techniques applied to one or more of optical, wireless, Bluetooth, and / or cellular signals received from respective transmitters located at different portions of the work site.

[0026] Fuel sensor 106 may be configured to determine an amount of fuel remaining in a fuel store such as a fuel tank associated with a combustion engine of a combustion engine powered compactor 10. Battery sensor 108 may be configured to determine an amount of power that one or more batteries of an electrical machine driven or hybrid compactor 10 (e.g., driven by both a combustion engine and an electric engine). For example, battery sensor 108 may be configured to measure a voltage, a current, a state of charge, or any other operational characteristic of one or more batteries to determine an amount of electrical power that can be delivered by the one or more batteries prior to replacement or recharging of the one or more batteries. Compactor 10 that includes a power source 26 that is a combustion engine may not include battery sensor 108. Likewise, compactor 10 that includes a power source 26 configured to drive only an electric engine may not include fuel sensor 106. Compactor 10 that is hybrid and includes both a combustion engine and an electric engine may include one or more of each of fuel sensor 106 and battery sensor 108.

[0027] Vibration sensor 110 may be configured to measure an angular separation between weights located within vibratory mechanism 24. Vibration sensor 110 may also be configured to determine a rotational speed of the weights located within vibratory mechanism 24.

[0028] Back-end control system 60 may include processor 112, memory device 114, and communication interface 116, which may have similar structural and / or functional characteristics as those of processor 90, memory device 92, and communication interface 94, respectively, of control module 80 of compactor 10. Back-end control system 60 may be located remote from a work site and from compactor 10 and may communicate with control module 80 of compactor 10 via communication interface 116 and network 70. In some embodiments, back-end control system 60 may include input devices and display devices similar to input devices 82 and display devices 84, respectively. In some embodiments, processor 112 of back-end control system 60 may receive measurements from one or more sensors, for example, 100, 102, 104, 106, 108, and / or 110, via network 70 and communications interface 116, and may perform some or all the functions performed by processor 90 of compactor 10. In some embodiments, processor 112 of back-end control system 60 may transmit data, commands, or signals via communications interface 116 and network 70 to compactor 10 to adjust one or more operating parameters of compactor 10.

[0029] Back-end control system 60 may include database 120. Database 120 may be configured to store instructions for execution by processor 112. Database 120 may also be configured to store the one or more inputs received from one or more input devices, from sensors such as 100, 102, 104, 106, 108, and / or 110, current and / or historical information including, for example, compaction values and their variations over time, variation of compaction values with forward and / or reverse passes of one or more compactors, compaction values obtained over time for a plurality of compactors 10, soil conditions, temperature conditions, weather information associated with the compaction values, and / or other parameters indicative of the functioning of one or more compactors, and / or of the compaction work performed at one or more work sites. Database 120 may also store current locations and / or historical locations over time for one or more compactors at one or more worksites. In some embodiments, database 120 may store information regarding operational parameters (e.g., ground speed, engine speed, fuel consumption amount, time taken to complete a task, change in compaction value for each forward and / or reverse pass) for a plurality of compactors 10 alone or in association with respective operators that may have operated those compactors 10.

[0030] Network 70 may include one or more of any of various types of networks for communication of information, such as a cellular network (e.g., 2G, 3G, 4G, or 5G), a satellite network, a Wi-Fi network, a WiMAX network, a Bluetooth network, a near-field communication (NFC) network, a low-power wide-area networking (LPWAN) network, a mobile network, a terrestrial microwave network, or a wireless ad hoc network. Network 70 may include an Internet Protocol (IP) based network. Network 70 may be configured to allow exchange of data, and / or signals between control modules 80 of one or more compactors 10 and back-end control system 60.

[0031] Although only one compactor control system 40 has been illustrated in FIG. 2, work site control system 50 may include any number of compactors 10 such that respective compactor control systems 40 of compactors 10 may exchange software, instructions, and / or data with back-end control system 60 and / or with each other. Similarly, although only one back-end control system 60 and database 120 is illustrated in FIG. 2, work site control system 50 may include any number of back-end control systems 60 and databases 120 that may be configured to exchange software, instructions, and / or data with each other or with one or more compactor control systems 40 associated with respective ones of compactors 10.INDUSTRIAL APPLICABILITY

[0032] Work site control system 50 of the present disclosure may be used to control operations of one or more compactors 10 and / or other constructions machines operating at a work site. In some embodiments, compactor control system 40 of work site control system 50 may be configured to control operations of one or more compactors 10 autonomously and / or in conjunction with an operator of a respective compactor 10, wherein the operator is capable of providing manual inputs to control operations of the compactor 10. In particular, one or more compactors may traverse over the same or different portions of work surface 30 to compact material in work surface 30. The one or more compactors 10 may be required to make multiple passes over all or a portion of work surface 30 to achieve a target compaction value for the material in work surface 30. One or more of compactor control system 40, work site control system 50, and / or back-end control system 60 may be configured to determine a current compaction value associated with work surface 30, determine a number of compaction passes required to achieve a target compaction value, and control operations of the one or more compactors 10 to ensure the target compaction value is achieved for work surface 30. Exemplary methods of controlling operations of compactor 10 are discussed below.

[0033] FIG. 3 illustrates an exemplary method 300 of controlling operations of a compactor, for example, compactor 10 to achieve a target compaction value for a work surface, for example, work surface 30. For ease of explanation, method 300 is described with respect to a single compactor 10. However, method 300 may be similarly applied to a plurality of compactors 10 that may operate at a work site. The order and arrangement of steps of method 300 is provided for purposes of illustration. As will be appreciated from this disclosure, modifications may be made to method 300 by, for example, adding, combining, removing, and / or rearranging the steps of method 300. Method 300 may be executed by processor 90 by, for example, executing one or more instructions stored in a memory device 92 associated with control module 80 of compactor 10. In some embodiments, some or all the steps of method 300 may additionally or alternatively be executed by processor 112 of back-end control system 60 by, for example, executing one or more instructions stored in a memory device 114 or database 120.

[0034] Method 300 may include a step of receiving a target compaction value (Step 302). Target compaction value may be provided as a target MDP or CMV value to processor 90 and / or processor 112. For example, in some embodiments, processor 90 of compactor 10 may receive the target compaction value from an operator of compactor 10 via one or more input devices 82 and / or via touchscreen display device 84. In some embodiments, processor 90 of compactor 10 may transmit the target compaction value via communications interface 94 and network 70 to processor 112 of back-end control system 60. In some embodiments, processor 112 of back-end control system 60 may receive the target compaction value from an operator located in a back office remote from the work site via one or more input devices associated with back-end control system 60. In some embodiments, back-end control system 60 may transmit the target compaction value received by processor 112 via communications interface 116 and network 70 to processor 90 of compactor 10. As another example, in some embodiments, processor 90 of compactor 10 may receive the target compaction value from another processor 90 of a different compactor 10 or from database 120 via network 70.

[0035] Method 300 may include a step of receiving a current compaction value and / or receiving previous compaction values (Step 304). For example, compaction sensor 100 may be configured to measure a current compaction value for work surface 30, which may be a MDP or CMV value. Compaction sensor 100 may send the determined current compaction value to processor 90 of compactor 10. In some embodiments, processor 90 may also transmit the determined current compaction value to processor 112 of back-end control system 60.

[0036] Previous compaction values refer to compaction values, for example, measured by compaction sensor 100 during one or more previous passes of compactor 10 over all or a portion of work surface 30. Thus, for example, during each forward or reverse pass of compactor 10 over work surface 30, compaction sensor 100 may measure one or more compaction values, which may be stored in memory device 92. These compaction values measured during a prior time period or during a previous forward or reverse pass of compactor 10 over work surface 30 constitute, for example, previous compaction values. In some embodiments, the measured compaction values may be transmitted, for example, via communications interface 94 and network 70 to back-end control system 60, which in turn may store the measured compaction values in memory device 114 or database 120. Receiving previous compaction values may include, for example, processor 90 accessing the stored previous compaction values from memory device 92, or receiving the previous compaction values from back-end control system 60 via communications interface 116 and network 70. In some embodiments, receiving previous compaction values may include, for example, processor 112 accessing the stored previous compaction values from memory device 114 or database 120, or receiving the previous compaction values from control module 80 of compactor 10 via communications interface 94 and network 70.

[0037] Method 300 may include a step of determining a required number of compaction passes, NR, to achieve the target compaction value (Step 306). In some embodiments, processor 90 may determine a required number of passes, NR, of compactor 10 to achieve the target compaction value for work surface 30 based on one or more of the current compaction value and / or the previous compaction values received, for example, in step 304. For example, processor 90 may determine a trend of compaction values based on the current compaction value and the previous compaction values, and further determine a rate of change of the compaction value for every forward and / or reverse pass of compactor 10 over work surface 30. Processor 90 may also determine the number of required compaction passes, NR, based on the current compaction value, the target compaction value, and the determined rate of change of the compaction value. In some embodiments, processor 90 may determine the trend based on previous compaction values measured during forward passes of compactor 10. In some embodiments, processor 90 may determine the trend based on previous compaction values measured during reverse passes of compactor 10. Alternatively, in some embodiments, processor 90 may determine the trend based on previous compaction values measured during some or all of both forward and reverse passes of compactor 10.

[0038] In some embodiments, processor 90 may determine the required number of compaction passes, NR, using a lookup table that may relate the current compaction value with the required number of compaction passes based on one or more other parameters, for example, ground speed, vibration amplitude, vibration frequency, weight of roller 22, or compactor 10, soil type, weather conditions, and or other parameters that may affect the compaction value of work surface 30. In some embodiments, processor 90 may execute one or more trained machine learning models that may receive at least the current measured value as input and provide the required number of compaction passes, NR, as an output. The one or more trained machine learning models may employ learning algorithms, for example, classification algorithms, data regressions algorithms, mathematical embedding algorithms, natural language processing algorithms, support vector machines, random forests, nearest neighbors algorithms, deep learning algorithms, artificial neural network algorithms, convolutional neural network algorithms, recursive neural network algorithms, linear machine learning models, non-linear machine learning models, ensemble algorithms, and so forth.

[0039] The one or more machine learning models may be trained using a training data set that may relate particular current compaction values with the required number of compaction passes to achieve particular target compaction values for various parameters. Such parameters may include, for example, ground speed, vibration amplitude, vibration frequency, weight of roller 22 or compactor 10, soil type, historical information including compaction values and their variations over time, compaction values obtained over time for a plurality of compactors, soil conditions, temperature conditions, weather information associated with the compaction values, operational parameters of compactors (e.g., ground speed, engine speed, fuel consumption amount, time taken to complete a task), and / or other parameters.

[0040] In some embodiments, processor 90 may determine a remaining area to be compacted based on, for example, a width of work tool 18, a ground speed of compactor 10, and the required number of compaction passes determined as discussed above. In some embodiments, processor 90 may determine an amount of time required to achieve the target compaction value on work surface 30 based on, for example, the required number of compaction passes and a ground speed of compactor 10. As also explained below, in some embodiments, processor 90 may determine an amount of fuel required by a combustion engine of compactor 10 for completing the required number of passes of compactor 10 over work surface 30 to achieve the target compaction value for work surface 30. For example, processor 90 may determine the amount of fuel required based on a fuel consumption rate of the combustion engine. Similarly, as explained below, in some embodiments, processor 90 may determine an amount of battery power required by an electric engine driven compactor 10 for completing the required number of passes and achieving the target compaction value for work surface 30. Although the various processes of step 306 have been discussed with reference to processor 90 of compactor 10, some or all of the processes described above for step 306 may additionally or alternatively be performed by processor 112 of back-end control system 60.

[0041] Method 300 may include a step of determining whether the required number of compaction passes NR is greater than a threshold number of required compaction passes, NT (Step 308). For example, in some instances, conditions of the material under work surface 30 may be such that the target compaction value may not be achievable even after compactor 10 passes over work surface 30 several times. This may happen, for example, when the material under work surface 30 contains very hard materials (e.g., large rocks, concrete, or metallic objects). In such cases, it may be desirable to not drive compactor 10 unnecessarily over work surface 30 for multiple compaction passes. Processor 90 may detect such a condition, for example, when a rate of change of compaction values is very small, giving rise to a very large number of required compaction passes, NR. The threshold number of required compaction passes, NT, may be determined based on soil conditions, weather conditions, temperature, or any other conditions that may affect the ability of materials under work surface 30 to be compacted. In some embodiments, the threshold number of required compaction passes, NT, may be determined based on a lookup table or using the one or more machine learning models described above. When processor 90 determines that the required number of compaction passes NR is greater than a threshold number of required compaction passes, NT (Step 308: YES), processor 90 may activate alert device 86 to generate an audio or audio visual alert to an operator of compactor 10. In some embodiments, the audio alert may be in the form of an alarm sound played by an audio device installed in compactor 10. In some embodiments, the audio alert may be in the form of an icon, video, or graphical symbol that may be displayed on the one or more display devices 84 of compactor 10. In some embodiments, additionally or alternatively, processor 90 may activate an alert device associated with one or more input devices 82 of compactor 10 to provide haptic feedback to an operator of compactor 10. In some embodiments, processor 90 may transmit a signal to processor 112 indicating that compactor 10 will be unable to complete the compaction work. After activating alert device 86 or providing haptic feedback to the operator of compactor 10, method 300 may end. When processor 90 determines, however, that the required number of compaction passes NR is not greater than a threshold number of required compaction passes, NT (Step 308: NO), method 300 may proceed to step 310.

[0042] Method 300 may include a step of displaying an indicator on one or more display devices 84 associated with compactor 10 or on one or more display devices associated with back-end control system 60 (Step 310). The displayed indicator may be representative of the required number of compaction passes. For example, in some embodiments the indicator may be the required number of compaction passes. In some embodiments, the displayed indicator may additionally or alternatively include the remaining area to be compacted, the amount of time required to achieve the target compaction value, the amount of fuel required to complete the required number of compaction passes, and / or the amount of battery power required to complete the required number of compaction passes. In some embodiments, processor 90 or 112 may determine a percentage of remaining work. For example, processor 90 or 112 may determine the percentage of remaining work as a ratio of the required number of compaction passes NR relative to a total number of compaction passes (e.g. NR+number of compaction passes already completed by compactor 10). In some embodiments, determine the percentage of remaining work as a ratio of the remaining area to be compacted relative to the total area to be compacted (e.g., an area of work surface 30). In some embodiments, the indicator may include the percentage of remaining work as determined by processor 90 or 112. The indicator may be displayed in the form of an alphanumeric string, an icon, and / or a graphical symbol. Some or all of the processes described for step 310 may additionally or alternatively be performed by processor 112 of back-end control system 60.

[0043] Method 300 may include a step of determining an amount of available power, “QA,” for compactor 10 (Step 312). For example, in some embodiments, processor 90 may receive signals indicative of an amount of fuel remaining in a fuel tank of a combustion engine driven or hybrid compactor 10 from fuel sensor 106. The amount of remaining fuel may be representative of an amount of available power QA for compactor 10. In some embodiments, processor 90 may receive signals indicative of a remaining battery level for an electric engine driven or hybrid compactor 10 from battery sensor 108. The remaining battery level may be in the form of a battery voltage, battery current, battery state of charge, or other parameter representative of the remaining electrical power that can be delivered by one or more batteries of compactor 10. The remaining battery level may be representative of an amount of available power QA for compactor 10. Some or all of the processes described for step 312 may additionally or alternatively be performed by processor 112 of back-end control system 60.

[0044] Method 300 may include a step of determining an amount of power required for completing the required number of passes, “QR,” for compactor 10 (Step 314). For example, in some embodiments, processor 90 may determine an amount of power required to complete one pass over work surface 30 based on the amount of power used to complete prior passes of compactor 10 over work surface 30. Processor 90 may also determine the amount of power required (QR) to complete the required number of passes determined, for example, in step 306 based on the amount of power required to complete each pass. For example, based on the amount of fuel consumption for each pass of compactor 10, processor 90 may determine the amount of fuel required to complete the required number of passes determined, for example, in step 306. The amount of fuel required may be representative of the amount of power required (QR). As another example, based on the amount of voltage drop or electrical current dissipated from the one or more batteries associated with compactor 10, processor 90 may determine the battery voltage, electrical current, state of charge, or other battery characteristic required to complete the required number of passes determined, for example, in step 306. The battery voltage, electrical current, state of charge, or other battery characteristic required to complete the required number of passes may be representative of the amount of power required (QR). Some or all of the processes described for step 314 may additionally or alternatively be performed by processor 112 of back-end control system 60.

[0045] Method 300 may include a step of determining whether the amount of available power QA is less than the amount of required power QR (Step 316). For example, processor 90 may determine whether an amount of fuel remaining in a fuel tank of a combustion driven compactor 10 is less than the amount of fuel required for completing the required number of passes. In some embodiments, processor 90 may determine a difference between an amount of fuel remaining in the fuel tank and the amount of fuel required for completing the required number of passes. Processor 90 may compare the determined difference in the amounts of fuel to a fuel threshold. Processor 90 may determine that the amount of available power QA is less than the amount of required power QR when the determined difference in the amounts of fuel is less than the fuel threshold.

[0046] As another example, processor 90 may determine whether the battery voltage, electrical current, state of charge, or other battery characteristic of one or more batteries of an electric or hybrid compactor 10 is less than the required battery voltage, electrical current, state of charge, or other battery characteristic for completing the required number of passes. In some embodiments, processor 90 may determine a difference between the battery voltage, electrical current, state of charge, or other battery characteristic of one or more batteries of an electric or hybrid compactor 10 and the required battery voltage, electrical current, state of charge, or other battery characteristic, respectively, for completing the required number of passes. Processor 90 may compare the determined difference to a battery power threshold. Processor 90 may determine that the amount of available power QA is less than the amount of required power QR when the determined difference is less than the battery power threshold. Some or all of the processes described for step 316 may additionally or alternatively be performed by processor 112 of back-end control system 60.

[0047] When processor 90 or processor 112 determines that the amount of available power QA is less than the amount of required power QR (Step 316: YES), method 300 may proceed to step 318. In step 318, processor 90 or processor 112 may adjust at least one operating parameter of compactor 10. For example, processor 90 or 112 may adjust a ground speed, angular separation of weights or rotational speed of weights in vibratory mechanism 24, fuel air mixture in a combustion engine of compactor 10, amount of current being drawn from one or more batteries of compactor 10, and / or other operational characteristics of compactor 10 to ensure compactor 10 can complete the required number of passes before the amount of available power is exhausted (e.g., before compactor 10 runs out of fuel or before the one or more batteries of compactor 10 are drained and out of charge). For example, when the amount of remaining fuel in a combustion engine driven compactor 10 is not sufficient to allow compactor 10 to complete the required number of passes, a ground speed of the compactor may be increased and one or both of angular separation of weights or rotational speed of weights in vibratory mechanism 24 may be adjusted to impact larger forces on work surface 30. This may in turn increase a rate of change of compaction value for each pass of compactor 10 on work surface 30, thereby reducing the number of required compaction passes to achieve the target compaction value. Reducing the number of required compaction passes may help ensure that compactor 10 can complete the number of required compaction passes with the remaining amount of fuel. After adjusting at least one operating parameter, method 300 may proceed to step 320.

[0048] In some embodiments, processors 90, 112, or an operator may adjust at least one operating parameter of compactor 10 even when the amount of available power QA is greater than or equal to the amount of required power QR. For example, processor 90, 112, or an operator may alter one or both of angular separation of weights or rotational speed of weights in vibratory mechanism 24 may be adjusted to change the forces exerted on work surface 30 during each pass of compactor 10 over work surface 30. Changing the forces exerted on work surface 30 may change (e.g., increase or decrease) the change in compaction value of work surface 30 that may occur during each pass of compactor 10 over work surface 30. This in turn may change the number of required compaction passes to achieve the target compaction value for work surface 30. Thus, for example, if the change in compaction value of work surface 30 that may occur during each pass of compactor 10 over work surface 30 is increased, the number of required compaction passes may decrease, which in turn may require less amount of fuel or battery power for compactor 10.

[0049] In some embodiments, processors 90 or 112 may determine that the amount of available power QA continues to be less than the amount of required power QR even after adjusting at least one operating parameter. In such cases, processor 90 may activate alert device 86 to generate an audio or audio visual alert to an operator of compactor 10. In some embodiments, the audio alert may be in the form of an alarm sound played by an audio device installed in compactor 10. In some embodiments, the audio alert may be in the form of an icon, video, or graphical symbol that may be displayed on the one or more display devices 84 of compactor 10. In some embodiments, additionally or alternatively, processor 90 or 112 may activate an alert device associated with one or more input devices 82 of compactor 10 to provide haptic feedback to an operator of compactor 10. In some embodiments, processor 90 may transmit a signal to processor 112 indicating that compactor 10 will be unable to complete the compaction work. Processor 112 may in turn control operations of another compactor 10 and direct the other compactor 10 to proceed with compaction of work surface 30. In such cases, method 300 may additionally or alternatively continue to be executed on the other compactor 10.

[0050] Returning to step 316, when processor 90 or processor 112 determines that the amount of available power QA is not less than the amount of required power QR (Step 316: NO), method 300 may proceed to step 320.

[0051] In step 320, processor 90 or 112 may determine whether compactor 10 has completed the required number of passes (Step 320). When processor 90 or 112 determines that compactor 10 has completed the number of passes (Step 320: YES), method 300 may end. When processor 90 or 112 determines, however, that compactor 10 has not completed the required number of passes (Step 320: NO), method 300 may return to step 304 and continue to execute steps 304-320.

[0052] The disclosed compactor and method may allow for additional information to be provided to an operator of compactor 10 during compacting operations. For example, the disclosed compactor and method may may display an indicator that may provide additional information regarding a remaining amount of compaction work for work surface 30. Thus, for example, the indicator may display a required number of compaction passes, an amount of time required to complete the compaction work, and / or other information as discussed above. Such information may help ensure an operator of compactor 10 can make appropriate adjustments to the operational parameters of compactor 10 to ensure that compactor 10 can complete the compaction work, for example, by ensuring compactor 10 is capable of completing the required number of compaction passes. The disclosed compactor and method may also advantageously allow for autonomous control and adjustment of operational parameters of compactor 10 or an alternate compactor 10 such that either or both compactors 10 can complete the required number of compaction passes to achieve the target compaction value for work surface 30.

[0053] It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed compactor and control system. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the disclosed compactor and control system. It is intended that the specification and examples be considered as exemplary only, with a true scope being indicated by the following claims and their equivalents.

Claims

1. A compactor, comprising:a chassis;at least one work tool configured to support the chassis on a work surface;a power source configured to propel the at least one work tool over the work surface;at least one sensor configured to determine a compaction value associated with the work surface; anda control system, including a processor configured to:receive a target compaction value for the work surface;receive a current compaction value from the at least one sensor;determine a required number of compaction passes of the compactor travelling over the work surface to achieve the target compaction value based at least on the current compaction value and the target compaction value;display, on a display screen, an indicator representative of the required number of compaction passes; andadjust at least one operating parameter of the compactor such that an amount of available power in the power source is sufficient for the compactor to complete the required number of compaction passes.

2. The compactor of claim 1, wherein each of the current compaction value and the target compaction value is one of a machine drive power (MDP) value or a compaction meter value (CMV).

3. The compactor of claim 1, wherein the processor is further configured to:determine a rate of change of the compaction value based on the current compaction value and at least one previous compaction value; anddetermine the required number of compaction passes based on the determined rate of change of the compaction value.

4. The compactor of claim 3, wherein at least one of the current compaction value and the at least one previous compaction value is based on measurements during one of a forward pass of the compactor or a reverse pass of the compactor travelling over the work surface.

5. The compactor of claim 1, wherein the indicator includes one of the required number of compaction passes or a percentage of remaining work determined based on the required number of compaction passes.

6. The compactor of claim 1, whereinthe processor is further configured to determine a remaining area to be compacted based on a width of the at least one work tool and the required number of compaction passes, andthe indicator includes one of the determined remaining area or a percentage of remaining work determined based on the determined remaining area.

7. The compactor of claim 1, whereinthe processor is further configured to determine an amount of time required to reach the target compaction value based on the required number of compaction passes, andthe indicator includes the determined amount of time.

8. The compactor of claim 7, whereinthe power source is a combustion engine,the processor is further configured to determine an amount of fuel required by the combustion engine for the compactor to complete the required number of passes, andthe indicator includes the determined amount of fuel.

9. The compactor of claim 8, wherein the processor is further configured to:receive, from a fuel sensor, an amount of fuel available in a fuel tank of the compactor;determine a difference between the amount of fuel available and the amount of fuel required; andgenerate an alert when the difference is less than a fuel threshold.

10. The compactor of claim 9, wherein generating the alert includes one of displaying a visual indicator on the display screen, playing a sound, or providing haptic feedback to an operator of the compactor.

11. The compactor of claim 7, whereinthe power source includes a battery and an electric engine,the processor is further configured to determine an amount of battery power required by the electric engine for the compactor to complete the required number of passes, andthe indicator includes the determined amount of battery power.

12. The compactor of claim 11, wherein the processor is further configured to:receive, from a battery sensor, a signal indicative of an amount of available battery power;determine a difference between the amount of available battery power and the amount of battery power required; andgenerate an alert when the difference is less than a battery power threshold.

13. A control system for a compactor including a chassis, at least one work tool configured to support the chassis on a work surface, and a power source configured to propel the at least one work tool over the work surface, the control system comprising:a memory storing instructions; anda processor configured to execute the instructions stored in the memory to:receive a target compaction value for the work surface;receive a current compaction value from at least one sensor configured to determine a compaction value associated with the work surface;determine a required number of compaction passes of the compactor over the work surface to achieve the target compaction value based at least on the current compaction value and the target compaction value;display, on a display screen, an indicator representative of the required number of compaction passes; andadjust at least one operating parameter of the compactor such that an amount of available power in the power source is sufficient for the compactor to complete the required number of compaction passes.

14. The control system of claim 13, wherein the processor is further configured to:determine a rate of change of the compaction value based on the current compaction value and at least one previous compaction value; anddetermine the required number of compaction passes based on the determined rate of change of the compaction value.

15. The control system of claim 14, wherein at least one of the current compaction value and the at least one previous compaction value is based on measurements during one of a forward pass of the compactor or a reverse pass of the compactor travelling over the work surface.

16. The control system of claim 13, wherein the processor is further configured to determine at least one of:a remaining area to be compacted based on a width of the at least one work tool and the required number of compaction passes,an amount of time required to reach the target compaction value based on the required number of compaction passes,an amount of fuel required by a combustion engine of the compactor to complete the required number of compaction passes,an amount of battery power required by an electric engine of the compactor to complete the required number of compaction passes, andwherein the indicator includes at least one of the required number of compaction passes, the remaining area, the amount of time, the amount of fuel required, and the amount of battery power required.

17. A method of controlling operations of a compactor including a chassis, at least one work tool configured to support the chassis on a work surface, a power source configured to propel the at least one work tool over the work surface, the method comprising:receiving, using a processor, a target compaction value for the work surface;receiving, using the processor, a current compaction value from at least one sensor configured to determine a compaction value associated with the work surface;determining, using the processor, a required number of compaction passes of the compactor over the work surface to achieve the target compaction value based at least on the current compaction value and the target compaction value;displaying, on a display screen, an indicator representative of the required number of compaction passes;determining, using the processor, a first amount of power that is available from the power source to propel the compactor;determining, using the processor, a second amount of power that is required to propel the compactor for the required number of compaction passes; andadjusting, using the processor, at least one operating parameter of the compactor when the first amount of power is less than the second amount of power.

18. The method of claim 17, further including:determining a rate of change of the compaction value based on the current compaction value and at least one previous compaction value; anddetermining the required number of compaction passes based on the determined rate of change of the compaction value.

19. The method of claim 17, further including determining, by the processor using a machine learning model, the required number of compaction passes to achieve the target compaction value.

20. The method of claim 17, further including determining at least one ofa remaining area to be compacted based on a width of the at least one work tool and the required number of passes,an amount of time remaining before reaching the target compaction value based on the required number of passes,an amount of fuel required by a combustion engine of the compactor to complete the required number of passes,an amount of battery power required by an electric engine of the compactor to complete the required number of passes,wherein the indicator includes at least one of the required number of passes, the remaining area, the amount of time, the amount of fuel required, and the amount of battery power required.

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