Cold Planer Cut Depth Tracking via Optical Sensors

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Solution Overview

Problem

Existing paving systems are inefficient and inaccurate in determining actual cut depths and material volumes, leading to delays, safety risks, and increased costs due to manual measurements and incomplete volume calculations.

Innovation Solution

A system that uses sensors on a machine to generate cut profiles and determine actual cut depths and volumes by processing sensor data from both front and rear sensors, enabling real-time adjustments and more accurate material removal calculations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual measurement of cut depths is used, then personnel can obtain cut depth information, but safety risks and work delays increase

Engineering Contradiction:

Improvecut depth measurementVSAvoidsafety risks

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces manual mechanical measurement with an automated optical sensing system. Sensors mounted on the cold planer automatically capture images of the work surface and calculate cut depths, eliminating the need for personnel to physically measure cut depths while maintaining measurement accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables the cold planer to self-measure and self-monitor its own cutting performance. The automated image capture and processing system allows the machine to independently determine cut depths and provide real-time feedback to operators, reducing reliance on manual intervention.

Inventive Principle:

Principle #25Self-service

2Measurement precision

If manual measurement of cut depths is used, then cut depth information can be obtained, but work efficiency decreases due to delays

Engineering Contradiction:

Improvecut depth measurementVSAvoidwork efficiency

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The automated sensing system operates continuously as the cold planer moves along the work surface, capturing images and calculating cut depths in real-time without interrupting the milling operation. This eliminates the stop-start nature of manual measurements and maintains continuous productive action.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system replaces time-consuming manual measurement processes with automated optical sensing and computational analysis, dramatically reducing the time required to obtain cut depth information while maintaining measurement accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If estimates of material volume are used, then coordination of asphalt delivery can be attempted, but accuracy decreases leading to increased costs

Engineering Contradiction:

Improvecoordination of material deliveryVSAvoidmaterial volume determination

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The patent replaces estimation methods with automated optical measurement and computational volume calculation. The system uses sensor data to accurately determine the volume of material removed, providing precise information for coordinating asphalt delivery and reducing material waste or shortages.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Loss of information

If sensors are added to the machine, then real-time cut profile data can be obtained, but device complexity increases

Engineering Contradiction:

Improvecut profile informationVSAvoidsystem complexity

Core Design Contradiction:

Loss of informationVSDevice complexity

Solution Approach 1:

The sensor system is integrated into the existing cold planer control architecture, allowing the same hardware to serve multiple functions including cut depth measurement, volume calculation, and real-time feedback control. This reduces overall system complexity compared to separate dedicated systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent uses software processing and algorithms as intermediaries to translate raw sensor data into meaningful cut profile information. This software layer manages the complexity of data processing while presenting simplified information to operators and control systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11840810B2Tracking the environment around a machine to define actual cut profile

Publication Date: 2023.12.12 CATERPILLAR PAVING PROD INC

AI summary

When removing portions of a work surface at a worksite with a machine (e.g., such as a cold planer), is useful to know the actual cut depths on each edge of the cold planer and/or the volume of material that has been removed from a work surface. However, determining actual cut depths and/or volume removed is difficult, costly, and can be inaccurate, resulting in increased costs and inefficiencies at the worksite. Accordingly, the present disclosure describes systems and methods for enabling automatic control of cut depth of a machine via a machine-controlled feedback loop and improved determinations of actual volume of material removed by the machine.