Compactor Controller Detecting Aberrant Material Response
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional compactor machines struggle to detect aberrant compaction responses in work materials, leading to inefficient operations and potential structural issues due to undetected problems like voids, rocks, or inappropriate soil types, which can result in wasted effort, delays, and compromised material quality.
Innovation Solution
A method and system for a compactor machine that includes sensors to monitor compaction state after each pass, an electronic controller to determine an incipient compaction response, and trigger fault conditions if aberrant criteria are met, using compaction state data to assess load bearing capacity and detect unsuitable conditions in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If conventional compaction monitoring methods are used, then compaction quality can be assessed, but early detection of aberrant conditions is not possible, leading to wasted effort and delays
Solution Approach 1:
The system performs preliminary analysis of compaction response during the compaction process itself, rather than waiting for post-compaction testing. By monitoring compaction state after each pass and comparing against predicted responses, the system detects aberrant conditions early in the process, preventing wasted effort on unsuitable material.
Solution Approach 2:
The system implements continuous feedback by comparing actual compaction state measurements with predicted compaction response. This real-time feedback loop enables early detection of deviations from expected behavior, allowing operators to identify and correct aberrant conditions before they result in failed compaction projects.
2Productivity
If compaction continues without detection of aberrant conditions, then productivity is maintained, but compaction quality deteriorates and structural problems occur
Solution Approach 1:
The system provides continuous feedback on compaction quality by comparing actual measurements with predicted responses. This enables real-time quality assurance without interrupting the compaction workflow, as the system processes data and generates alerts during normal operation rather than requiring stopping for manual testing.
Solution Approach 2:
The system replaces manual quality inspection methods with automated electronic monitoring and analysis. Sensors and processors continuously assess compaction state, eliminating the need for operators to manually evaluate compaction quality and reducing human error in quality assessment.
3Measurement precision
If post-compaction testing methods are used, then compaction quality can be verified, but remediation requires re-compaction or additional processing steps
Solution Approach 1:
The system performs quality assessment during the compaction process itself, identifying problems before they become permanent failures. By detecting aberrant conditions early, the system enables simple remedial actions during compaction rather than requiring complex post-compaction remediation procedures.
Solution Approach 2:
The system enables self-monitoring and self-assessment of compaction quality through integrated sensors and analysis algorithms. This automated self-service capability eliminates the need for separate manual testing procedures and reduces dependency on external quality verification methods.
Data Source
AI summary
A method of operating a compactor includes determining a value indicative of a compaction state of a region of work material after each of a plurality of compactor passes, and triggering a compaction fault condition if an incipient compaction response satisfies aberrant compaction criteria. A machine includes an electronic controller configured to trigger a compaction fault condition responsively to sensor input signals indicative that aberrant compaction criteria are satisfied by an incipient compaction response of a work material.