Pneumatic Compactor Weight Sensing via Cylinder Pressure
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Solution Overview
Problem
Operators of pneumatic compactor machines face challenges in accurately estimating and managing ground contact pressures, leading to degraded performance due to inaccurate tire pressure estimates for varying compaction surface conditions, which results in inefficient operation and suboptimal compaction results.
Innovation Solution
A weight sensing system for pneumatic compactors that includes a pressure sensor connected to a pneumatic cylinder, a controller to determine compaction weight based on pressure signals, weight distribution, and fixed cylinder volume, and a display unit to provide real-time compaction weight information to the operator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If operators estimate contact pressure manually using charts and weight calculations, then the system complexity remains low, but the measurement precision of ground contact pressure deteriorates
Solution Approach 1:
The patent replaces manual mechanical estimation methods with electronic pressure sensors and digital processing systems. Pressure sensors mounted on the compactor frame directly measure ground contact pressure, eliminating the need for manual weight calculations and chart-based estimation, thereby significantly improving measurement precision while accepting increased system complexity through electronic instrumentation.
2Adaptability or versatility
If operators use fixed tire pressure settings, then the ease of operation is maintained, but the adaptability to varying compaction surface conditions deteriorates
Solution Approach 1:
The patent implements a feedback system where pressure sensors continuously measure ground contact pressure and transmit data to a display unit. This real-time feedback enables operators to adjust tire pressure dynamically based on actual compaction conditions, improving adaptability while maintaining ease of operation through automated measurement and clear visual presentation of pressure data.
Solution Approach 2:
The system transitions from static, fixed tire pressure settings to dynamic, real-time pressure monitoring and adjustment. The pressure sensors and display system enable continuous adaptation to varying compaction surfaces, allowing operators to optimize tire pressure on-the-fly without complex manual calculations, thereby enhancing versatility while preserving operational simplicity.
3Productivity
If accurate weight sensing is implemented using pressure sensors and controllers, then the productivity through reduced passes is improved, but the device complexity increases
Solution Approach 1:
The patent implements a self-service weight sensing system where pressure sensors automatically measure ground contact pressure and the controller autonomously calculates compaction weight. The system requires minimal operator intervention beyond monitoring the display, enabling accurate weight determination and optimized pass planning. This automation improves productivity by reducing the number of passes needed while managing device complexity through integrated sensor-controller-display architecture.
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
The system enables accurate and dynamic adjustment of compaction weight, improving operational efficiency and reducing the number of passes required for effective compaction, thereby enhancing the compactor's performance and reducing operational costs.
Implementation Method 1
a pressure sensor in communication with a pneumatic cylinder. The pressure sensor is configured to generate a signal indicative of a pressure exerted on the pneumatic cylinder
Data Source
AI summary
A weight sensing system for a pneumatic compactor is provided. The weight sensing system includes a pressure sensor in communication with a pneumatic cylinder. The pressure sensor is configured to generate a signal indicative of a pressure exerted on the pneumatic cylinder. Further, a controller is communicably coupled to the pressure sensor. The controller is configured to receive the signal indicative of the pressure exerted on the pneumatic cylinder. The controller is also configured to determine a compaction weight of the pneumatic compactor based on the received signal, a weight distribution on the pneumatic compactor, and a fixed volume of the pneumatic cylinder.