Compactor Roller Contact Sensor for Substrate Rigidity Assessment

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Solution Overview

Problem

Existing compactor rollers struggle to accurately determine the contact state and degree of compaction on substrates like soil or asphalt, leading to inefficient compaction processes as the contact width decreases with increasing rigidity of the substrate, making it difficult to assess and modify the compaction state effectively.

Innovation Solution

A device equipped with a rotatable compactor roller and contact sensors around its axis, generating signals for contact start and end, allowing for the determination of the contact size and degree of compaction by analyzing the portion of the acquisition circumference in contact with the substrate, which can be used to infer the compaction state and adjust compaction measures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the substrate rigidity increases, then the compaction quality improves, but the contact width of the compactor roller decreases

Engineering Contradiction:

Improvesubstrate rigidityVSAvoidcontact width

Core Design Contradiction:

StrengthVSLength of moving object

Solution Approach 1:

The patent implements a feedback mechanism by using contact sensors to detect the contact width between the compactor roller and substrate, then using this information to determine and communicate the compaction state. This allows the system to adapt to varying substrate conditions by providing real-time feedback on compaction effectiveness, enabling operators to adjust operations based on actual contact conditions rather than relying solely on theoretical rigidity parameters.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces direct mechanical measurement of compaction state with a sensor-based detection system. Instead of relying purely on mechanical indicators of compaction, the system uses contact sensors to optically or electrically detect the contact width and translate it into compaction state information, substituting mechanical assessment with a more precise sensing and signal processing approach.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Length of moving object

If the contact width decreases, then the penetration depth increases, but the measurement accuracy of compaction state deteriorates

Engineering Contradiction:

Improvepenetration depthVSAvoidcompaction state measurement

Core Design Contradiction:

Length of moving objectVSMeasurement precision

Solution Approach 1:

The patent introduces an intermediary evaluation system that translates the contact width measurement into a compaction state determination. The contact sensors detect the actual contact width, which serves as an intermediary parameter, and this measurement is then processed through evaluation logic to determine the overall compaction state, allowing indirect but accurate assessment of compaction quality even when direct contact width is small.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent transitions from measuring only contact width in one dimension to evaluating compaction state by considering the temporal pattern of contact across multiple dimensions. By monitoring contact start and end points over time and analyzing the duration and consistency of contact, the system adds temporal and pattern-based dimensions to the measurement, enabling accurate compaction assessment even when contact width is reduced.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Measurement precision

If contact sensors are added to determine contact state, then the compaction assessment capability improves, but the device complexity increases

Engineering Contradiction:

Improvecontact state detectionVSAvoidsensor system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent applies universality by designing contact sensors that serve multiple functions: they detect contact start, detect contact end, measure contact width, and provide temporal patterns for compaction state evaluation. This multi-functionality reduces the need for separate sensors for each measurement task, thereby limiting the increase in device complexity while maintaining improved measurement precision.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The contact sensors are positioned to automatically detect contact conditions during the normal operation of the compactor roller without requiring additional actuators or complex positioning mechanisms. The sensors self-activate based on the mechanical contact between the roller and substrate, eliminating the need for separate activation systems and reducing overall device complexity while maintaining detection capability.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS9650747B2Device and procedure to determine a size of contact representing the contact state of a compactor roller upon the substrate to be compacted

Publication Date: 2017.05.16 HAMM AG

AI summary

Device to determine a size of contact representing a contact state between a compactor roller and a substrate to be compacted, encompassing a compactor roller rotatable in at least one acquisition circumference area around a compactor roller axis and at least one contact sensor generating a contact signal, wherein the contact signal indicates a contact start and a contact end of an acquisition circumference area upon the substrate to be compacted.