Transport Conveyor Detection for Milling Machine Collision Avoidance
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Solution Overview
Problem
Automotive milling machines face challenges in coordinating with transport vehicles due to difficulties in communicating and synchronizing the milling process, especially with varying vehicle configurations and positions, leading to potential collisions and operational distractions for the operator.
Innovation Solution
A detection device is installed on the bottom side of the transport conveyor, which generates an activation signal when approaching an object, allowing for automatic control adjustments to prevent collisions and ensure safe discharging of milled material, regardless of vehicle orientation or shape, using flexible or rigid sensing elements coupled with sensors to control the conveyor's speed and angle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If the operator manually coordinates the milling machine with the transport vehicle using horn signals and visual monitoring, then communication between operator and driver is possible, but the operator becomes distracted from the milling operation and collision risk increases
Solution Approach 1:
The transport vehicle's detection device autonomously monitors its own position relative to the milling machine and automatically triggers horn signals or alarm signals without operator intervention. The system serves itself by detecting potential collisions and initiating warning signals independently.
Solution Approach 2:
The detection device continuously monitors the position of the transport vehicle relative to the milling machine and provides real-time feedback through automatic horn signals or alarm signals. This closed-loop feedback system ensures timely warnings without requiring operator attention.
2Reliability
If the transport vehicle driver stops the vehicle upon hearing a horn alert, then collision prevention is improved, but false stopping may occur due to other vehicles' horn alerts
Solution Approach 1:
The detection device is divided into separate functional units: a horn signal generator mounted on the milling machine and a detection device with alarm signal generator on the transport vehicle. This segmentation allows the transport vehicle to independently detect and respond to warnings without relying on ambient horn signals from other sources.
Solution Approach 2:
The detection device acts as an intermediary between the milling machine and the transport vehicle driver. Instead of the driver directly responding to horn signals that could come from any source, the detection device mediates by providing targeted alarm signals based on actual proximity detection.
3Productivity
If the operator adjusts the slewing angle, elevation angle, and conveying speed of the transport conveyor, then the loading of the transport vehicle is optimized, but the operator is further distracted from the milling operation
Solution Approach 1:
The transport vehicle autonomously optimizes its loading parameters by detecting the milling machine's position and automatically adjusting the slewing angle, elevation angle, and conveying speed. The system performs these adjustments independently without operator intervention.
Solution Approach 2:
The detection device provides real-time feedback on the relative position between the transport vehicle and milling machine, enabling automatic adjustment of loading parameters. This feedback loop allows the system to self-optimize loading efficiency without operator involvement.
4Reliability
If ultrasonic measuring systems are used to measure the distance between the milling machine and transport vehicle, then collision avoidance is improved, but the systems fail when the transport vehicle is laterally offset or has non-vertical rear wall
Solution Approach 1:
The patent replaces ultrasonic distance measurement systems with a detection device that uses optical or electromagnetic fields to detect the presence and position of the milling machine. This substitution eliminates the limitations of ultrasonic systems regarding lateral offsets and non-vertical surfaces.
Solution Approach 2:
The detection device is designed to detect various configurations of the milling machine and transport vehicle, making it universally applicable regardless of lateral offsets, vehicle orientations, or rear wall angles. The system adapts to different scenarios without requiring precise distance measurements.
Data Source
AI summary
In an automotive milling machine, comprising a machine frame, comprising a controller for the travelling and milling operation, comprising a working drum, comprising a transport conveyor for discharging the milled material milled off by the working drum onto a loading surface of a transport vehicle comprising a rear wall, where the transport conveyor is slewable, relative to the machine frame, about a first axis extending essentially horizontally under an elevation angle, and sideways about a second axis extending orthogonally to the first axis under a slewing angle, it is provided for the following features to be achieved: a detection device is arranged on the bottom side of the transport conveyor, where said detection device is used to initiate an activation signal in case of the transport conveyor approaching an object, in particular, the rear wall of the loading surface.