Compactor Sensor Feedback Control for Consistent Soil Compaction
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Solution Overview
Problem
Manual determination of compaction parameters by operators in compactors leads to errors and uneven compaction, especially on uneven surfaces with varying materials, resulting in under or over compaction of work areas.
Innovation Solution
A system with first and second compaction sensors and a controller that determines compaction efforts based on real-time data from the sensors, adjusting the vibratory mechanism to achieve target compaction by correlating variance in compaction data with initial efforts, allowing for automated and optimized compaction processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual determination of compaction parameters by operators is used, then operator judgment and observation can guide compaction, but errors and uneven compaction occur resulting in under or over compaction
Solution Approach 1:
The compactor system performs self-diagnosis and self-adjustment by using sensors to detect compaction characteristics and automatically modifying vibratory parameters. The system serves itself by eliminating the need for external operator judgment, with the control system making real-time adjustments based on sensor feedback from the work area.
Solution Approach 2:
The patent replaces the manual mechanical judgment system with an automated sensor-based detection and control system. Sensors detect compaction characteristics and the control system processes this data to automatically adjust vibratory parameters, substituting human operator skills with an automated electromechanical system.
2Productivity
If operators rely on their own judgements and observations to determine compaction parameters, then compaction can be performed, but extensive training is required and errors are prone
Solution Approach 1:
The system eliminates the need for operator training by implementing self-service automation. The control system with integrated sensors automatically detects work area characteristics and adjusts compaction parameters without requiring human expertise, thereby eliminating training time while maintaining or improving productivity.
Solution Approach 2:
The patent implements a feedback loop where sensors continuously monitor compaction characteristics and provide data to the control system. This real-time feedback enables automatic adjustment of vibratory parameters, eliminating the need for trained operators to make judgments and allowing untrained operators to achieve consistent compaction results.
3Adaptability or versatility
If manual compaction parameter determination is used on uneven surfaces with different materials, then compaction operation can proceed, but appropriate operating parameters become challenging to determine leading to uneven compaction
Solution Approach 1:
The patent uses sensor feedback to continuously detect work area characteristics such as material type, density, and compaction state. The control system processes this feedback data and automatically adjusts vibratory parameters including amplitude and frequency to match the specific conditions of uneven surfaces with different materials, achieving precise adaptation without manual intervention.
Solution Approach 2:
The system dynamically adjusts compaction parameters in real-time based on detected work area conditions. The vibratory mechanism transitions from static fixed parameters to dynamic adjustable parameters that continuously adapt to changing material characteristics, allowing the compactor to handle uneven surfaces with different materials effectively.
Data Source
AI summary
The disclosure is directed towards a system for compacting a work area. The system includes a compactor, a first compaction sensor positioned on a forward end of the compactor, a second compaction sensor positioned on a rearward end of the compactor, and a controller. The controller is configured to receive a first compaction data associated with the work area from the first compaction sensor. The controller is further configured to determine a first compaction effort based on the first compaction data and control the compactor to perform compaction with the determined first compaction effort. The controller is configured to receive a second compaction data associated with a compacted first portion from the second compaction sensor and determine a variance between the first and the second compaction data. Furthermore, the controller is configured to determine a correlation between the variance and the first compaction effort to determine a second compaction effort.