Bucket Agitation for Automated Payload Tip-off
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing loader-type machines face challenges in accurately and efficiently tipping off granular or powder materials during the automated payload tip-off process due to varying material properties, such as stacking, angle of repose, cohesion, and density, leading to inconsistent results and time-consuming operations, especially with materials like fine grained or powdery substances that are sticky and difficult to spill.
Innovation Solution
A method and system that control the motion of a bucket using electronically controlled actuators and an electro-hydraulic system, which receives sensor signals to detect the material weight and apply an agitation pattern with specific frequencies and amplitudes to shake the bucket, ensuring precise control and efficient tip-off by updating the remaining amount until it reaches the target weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If vibration is applied to the bucket before spilling to shake and loosen the material, then the desired load can be achieved within improved tolerance, but the operation becomes time consuming due to requiring multiple shaking cycles
Solution Approach 1:
The system applies vibration agitation to the bucket before the tip-off operation begins, preparing the material in advance by shaking and loosening it. This preliminary action ensures that when the actual spilling occurs, the material is already in an optimal state for controlled discharge, achieving the desired load tolerance without requiring multiple repeated shaking cycles during the tip-off process itself
2Ease of operation
If vibration is applied to shake and loosen the material before spilling, then material flow is improved, but the results are inconsistent depending on the type of materials making it unreliable
Solution Approach 1:
The system dynamically adjusts the vibration agitation parameters including frequency, amplitude, and duration based on the detected material type and real-time material behavior observations. This dynamic adaptation allows the same vibration mechanism to effectively handle different material types (rock, soil, sand, grain, etc.) with varying properties, ensuring consistent and reliable tip-off results across diverse materials
Solution Approach 2:
The system incorporates sensors and control systems that monitor material behavior during the tip-off process and provide feedback to adjust the vibration agitation parameters in real-time. This feedback mechanism allows the system to learn from each material type encountered and optimize the agitation approach, making the operation reliable and consistent across different material types rather than producing inconsistent results
3Measurement precision
If multiple shaking cycles are performed to spill material from the bucket, then the payload target is achieved, but the operation becomes time consuming
Solution Approach 1:
The system maintains continuous vibration agitation throughout the tip-off process rather than performing discrete intermittent shaking cycles. The vibration is applied continuously from the beginning of the tip-off until the payload target is achieved, ensuring that the material remains in a consistently loose and flowable state throughout the entire operation. This continuous action eliminates the need to stop and restart multiple times, significantly improving loading speed while maintaining payload target accuracy
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables predictable and efficient tip-off of materials, achieving a target load within minimal time and improved accuracy, even with challenging materials like fine grained or powdery substances, by adjusting the agitation pattern based on material type and weight, thereby optimizing the loading process.
Implementation Method 1
a bucket operated by an electro-hydraulic system
Implementation Method 2
generate a shaking motion of the bucket to spill granular or powder material
Data Source
AI summary
A wheel loader machine includes a bucket configured to hold a predetermined load of a granular or powder material, a hydraulic system having an electro-hydraulic actuator to move the bucket over tilt angles and to shake the bucket, a hydraulic sensor configured to detect hydraulic pressure, an interface configured to receive input parameters and to output status information of the bucket, and a controller. The input parameters including a target weight of the granular or powder material. The status information including weight of the granular or powder material in the bucket determined using the detected hydraulic pressure. The controller configured to control the hydraulic system to tilt the bucket to a predetermined tilt angle and to shake the bucket in accordance with an agitation pattern until the weight of the granular or powder in the bucket is at or below the target weight of the granular or powder material.