Cold Planer Rotor Collision Avoidance via Motion Detection
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Solution Overview
Problem
Existing cold planer systems lack effective methods to prevent rotor collisions during reverse propulsion, which can cause kickback and damage to the machine or objects, as they primarily rely on distance detection between the milling drum and the ground, failing to adequately sense and prevent collisions with objects in the path.
Innovation Solution
The implementation of a control system with sensors to detect the direction of motion and the presence of objects outside the milling chamber, generating signals to initiate a rotor collision avoidance mode, such as disengaging the rotor or altering its operation to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the milling rotor is left rotating during reverse motion to prepare for the next pass, then productivity is improved by avoiding shutdown and startup time, but the risk of rotor collision with objects increases causing kickback and potential damage
Solution Approach 1:
The control system performs preliminary detection of objects in the reverse path before the rotor completes its rotation. By detecting objects ahead of time during reverse motion, the system can prepare to disengage the rotor before collision occurs, maintaining productivity while preventing damage.
Solution Approach 2:
The system continuously monitors the reverse path for objects using sensors and provides real-time feedback to the control module. This feedback loop enables dynamic adjustment of rotor operation based on detected object positions, allowing the rotor to remain rotating when safe and disengage when objects are detected.
2Reliability
If the rotor is disengaged or slowed during reverse motion to prevent collision, then reliability is improved by avoiding kickback and damage, but productivity deteriorates due to shutdown and startup time and driveline wear
Solution Approach 1:
The system detects objects in the reverse path before the rotating rotor would reach them. By performing preliminary detection and only disengaging when necessary, the system avoids unnecessary shutdowns and startups, maintaining productivity while preventing collisions.
Solution Approach 2:
The control system dynamically adjusts rotor operation based on real-time object detection. The rotor remains rotating when the reverse path is clear and only disengages or slows when objects are detected, optimizing both productivity and reliability through adaptive control.
3Reliability
If distance detection between milling drum and ground surface is used to prevent kickback, then some protection is provided, but the system is limited and cannot effectively detect objects outside the ground surface area
Solution Approach 1:
The sensor system is designed to detect multiple types of objects in various positions during reverse motion, not just ground surface distance. The same detection system identifies rocks, debris, and other obstacles at different heights and distances, providing universal protection against all collision risks.
Solution Approach 2:
The system extends detection beyond the traditional ground surface plane by monitoring three-dimensional space in the reverse path. Sensors detect objects at various heights and distances, adding spatial dimensions to the detection capability beyond simple drum-to-ground distance measurement.
Data Source
AI summary
An example cold planer system includes a machine frame, a milling rotor disposed in a milling chamber, a first sensor, a second sensor and a control module. The control module comprises a processor and a controller. The processor is configured to receive a first signal indicative of a direction of motion of the machine, and a second signal indicative of whether an object is present in an object detection zone. The processor processes the first signal and the second signal to generate a control signal. The controller is configured to receive the control signal from the processor and to initiate a rotor collision avoidance mode if an object is present in an object detection zone.