Compactor Roller Motion Sensors Using Magnetic Coupling

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing soil compactor systems struggle to accurately determine the motion state of compactor rollers due to sensors being fixed to the frame rather than the roller, leading to incomplete information on vibration modes and motion forms.

Innovation Solution

A device with motion sensors arranged on the inside of the roller mantle, moving with it, and equipped with a radio-signal transmission apparatus and energy converter to transmit and power the sensors independently, allowing precise motion state detection without external energy sources.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If sensors are fixed to the frame rather than the roller, then the system structure is simpler and easier to implement, but the measurement precision of the roller motion state deteriorates

Engineering Contradiction:

Improvesensor installation simplicityVSAvoidroller motion state detection accuracy

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

The sensor housing is nested within the roller mantle, with the sensor positioned inside the hollow roller structure. This allows the sensor to move together with the roller while being protected by the roller mantle, achieving both accurate motion detection and structural integration without external cable connections.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The roller mantle acts as an intermediary structure that houses and protects the sensor while transmitting the roller's motion to the sensor. The magnetic coupling mechanism serves as an intermediary to transmit rotational position information from the rotating roller to the stationary sensor housing without physical cable connections.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If sensors are moveable with the roller mantle, then the measurement precision of the roller motion state improves, but the device complexity increases due to cable management and rotary connections

Engineering Contradiction:

Improveroller motion state detection accuracyVSAvoidcable connection and rotary lead complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The cable connection problem is extracted and eliminated by using magnetic coupling for position detection and radio signal transmission for data communication. This removes the need for rotary leads and cable management systems, significantly reducing device complexity while maintaining accurate motion detection.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Mechanical cable connections are replaced with magnetic coupling for rotational position detection and radio signal transmission for data communication. This substitution eliminates the need for physical rotary connections, reducing mechanical complexity and improving reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If motion sensors are positioned on the frame, then the system is easier to power with external energy sources, but the reliability of motion state detection deteriorates due to conditional information availability

Engineering Contradiction:

Improveenergy supply accessibilityVSAvoidmotion state detection consistency

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The system uses the roller's own motion energy to generate electrical power through a generator attached to the roller shaft. This self-powered approach eliminates dependence on external energy sources and ensures continuous operation, improving reliability while the radio transmission enables easy data access.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The sensor housing serves multiple functions: it houses the motion sensor, provides magnetic coupling for position detection, protects the sensor components, and integrates with the roller structure. This multi-functionality reduces the need for separate power and data transmission systems, improving reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution provides more accurate and robust motion state detection, reducing susceptibility to failure and simplifying the system design, enabling precise determination of compactor roller motion and improving compaction results.

Implementation Method 1

An energy converter apparatus to extract electric energy from the compactor roller motion to power the motion sensors and the radio-signal transmission apparatus

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS9222226B2Device for detecting the motion of a compactor roller of a soil compactor

Publication Date: 2015.12.29 HAMM AG

AI summary

A device for detection of the motion of a compactor roller (20) of a soil compactor (10) rotatable about an axis of rotation (A), where said roller comprises on one inside of a roller mantle (22) a plurality of motion sensors (ai) arranged in the circumferential direction around the axis of rotation (A) and at a spacing from each other and moveable with the roller mantle (22) around the axis of rotation (A).