Automated Sensor Switching for Construction Machine Milling Control
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Solution Overview
Problem
Existing grade control systems for construction machines, such as road milling machines, lack advanced functionality for efficiently switching between sensor subsets to maintain accurate milling depth and profile control, particularly in the presence of sensor failures or discontinuities in the design surface.
Innovation Solution
A method and system for a construction machine that includes a controller to automatically select and switch between sensor subsets based on a priority ranking, using a design surface data set and sensor inputs to maintain accurate milling depth and profile control, even in the presence of sensor failures or design surface discontinuities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual sensor switching is implemented, then operator control over sensor selection is improved, but operational complexity and response time increase
Solution Approach 1:
The system automatically monitors sensor status and performs sensor subset switching without operator intervention. The controller continuously evaluates sensor functionality and autonomously transitions between sensor subsets when failures are detected, eliminating the need for manual switching operations while maintaining full operator control through the automated decision-making process
2Loss of time
If automatic sensor switching is implemented, then response time to sensor failures is improved, but system complexity increases
Solution Approach 1:
The system employs continuous feedback monitoring of sensor status where the controller receives real-time information about sensor functionality. This feedback loop enables the system to automatically detect sensor failures and trigger appropriate sensor subset switching, achieving rapid response times through automated feedback-driven decision-making without requiring complex manual intervention systems
Solution Approach 2:
The system pre-configures multiple sensor subsets in advance, with each subset capable of independently performing the measurement function. When a sensor failure occurs, the system can immediately switch to a pre-prepared alternative subset, eliminating the need for complex real-time reconfiguration and enabling rapid response through pre-planned redundancy
3Reliability
If multiple sensor subsets are maintained, then system reliability during sensor failures is improved, but device complexity and cost increase
Solution Approach 1:
Multiple sensor subsets are configured to perform the same universal function of measuring ground surface profile and controlling milling depth. Each subset contains sensors that can independently execute the complete measurement and control task, allowing the system to maintain full operational reliability by switching between functionally equivalent subsets rather than requiring specialized redundant systems
Solution Approach 2:
The system dynamically changes operational parameters by switching between different sensor subsets based on real-time sensor status. When sensor failures are detected, the controller modifies the active sensor subset configuration parameter, transitioning to an alternative subset with different sensor combinations while maintaining the same control function, thereby achieving reliability through parameter adaptation rather than hardware redundancy
Data Source
AI summary
A construction machine uses a controller configured to determine a cross-sectional profile of a design surface at a selected position and orientation of a milling drum of the construction machine. The controller automatically determines a preferred sensor sub-set from a plurality of possible sensor sub-sets selected from a set of available sensors. The preferred sensor sub-set must be usable to create at least a portion of the cross-sectional profile of the design surface. The controller automatically maintains or switches control of the milling depth to use the preferred sensor sub-set.