Cold Planer Loading Control via Sensor Fusion
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Solution Overview
Problem
Current control systems for cold planers lack precision in communicating and managing the loading and transport of milled material, leading to inefficiencies and potential spillage due to imprecise communication methods between the milling machine and transport vehicles.
Innovation Solution
A control system that includes sensors to monitor material transfer and vehicle positioning, a communication device for real-time data exchange, and a controller to determine fill levels and generate commands for optimal loading and dispatch, ensuring accurate and continuous material transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If hand signals and horns are used for communication between cold planer and truck operators, then the system is simple and easy to operate, but the communication is imprecise and cannot convey complex information
Solution Approach 1:
The patent replaces manual communication methods (hand signals and horns) with an automated electronic control system that uses sensors, processors, and communication devices to exchange data between the cold planer and transport vehicles. This substitution of mechanical/manual systems with electronic automation directly resolves the contradiction by providing precise, complex information transfer while maintaining operational simplicity for the operators.
Solution Approach 2:
The patent introduces a communication device as an intermediary between the cold planer controller and transport vehicle controllers. This intermediary component enables structured, precise data exchange including fill level information, positioning data, and operational commands, resolving the communication precision issue while keeping the overall system architecture manageable through standardized interfaces.
2Manufacturing precision
If operators constantly communicate to ensure proper alignment and prevent spillage, then loading accuracy is maintained, but the process is time-consuming and reduces productivity
Solution Approach 1:
The patent implements a feedback mechanism where sensors on the transport vehicle continuously transmit fill level and positioning data to the cold planer controller. The controller processes this feedback information and automatically adjusts conveyor operation and provides guidance to the transport vehicle operator, maintaining loading accuracy without requiring constant manual communication and significantly improving loading efficiency.
Solution Approach 2:
The system enables the transport vehicle to self-report its fill level and positioning status through onboard sensors and communication devices. This self-service capability allows the cold planer controller to automatically manage the loading process based on real-time data from the transport vehicle, eliminating the need for continuous operator intervention and communication while maintaining precise loading control.
3Productivity
If the system provides comprehensive real-time data exchange between cold planer and transport vehicles, then loading efficiency and continuity are improved, but the device complexity increases
Solution Approach 1:
The patent employs a universal communication protocol and standardized data structures that enable the control system to handle multiple functions including fill level monitoring, positioning coordination, spillage prevention, and automated dispatch signaling. This multi-functionality approach allows comprehensive real-time data exchange through a unified system architecture, improving loading efficiency without proportionally increasing complexity through modular, reusable communication frameworks.
Data Source
AI summary
A control system for a cold planer having a conveyor configured to transfer material into a first receptacle is disclosed. The control system may include a first sensor configured to generate a first signal indicative of an amount of material being transferred into the first receptacle, a communication device configured to transfer information between the cold planer and the first receptacle, and a controller electronically connected to the first sensor and the communication device. The controller may be configured to receive an input from the first receptacle via the communication device and determine a fill level of the first receptacle based on the first signal and the input from the first receptacle.