Foldable Conveyor Load Sensing for Milling Material Tracking
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Solution Overview
Problem
Current milling machines lack an efficient method to accurately track and monitor the amount of milled material during operation, particularly due to limitations in sensing and measuring the load on foldable conveyors, which affects material removal efficiency and job monitoring.
Innovation Solution
A system that includes a foldable conveyor with sensors and a controller to measure the force acting on the conveyor sections, using sensors like pressure sensors and strain gauges to determine the amount of milled material, allowing for periodic sampling and calibration to accurately monitor material removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a tensile force measurement system is used at the conveyor connection (load pins or hydraulic cylinder), then the material tracking capability is provided, but the device complexity and measurement accuracy are limited
Solution Approach 1:
The patent replaces complex mechanical load measurement systems (load pins, hydraulic cylinders) with strain gauge sensors that directly measure force on the conveyor belt. This substitution simplifies the sensing system while improving measurement accuracy through direct strain measurement on the conveyor structure itself.
Solution Approach 2:
The conveyor belt structure itself serves as the measurement platform by incorporating strain gauges directly into the belt or its support structure. The conveyor's own mechanical response to material load becomes the sensing mechanism, eliminating the need for separate complex measurement apparatus.
2Loss of information
If no load sensing system is installed on the foldable conveyor, then the device complexity is reduced, but the ability to track and monitor milled material is lost
Solution Approach 1:
The patent uses strain gauges (electrical sensors) to replace the need for complex mechanical measurement systems. These sensors convert mechanical strain from material load into electrical signals, providing accurate material tracking information with minimal added complexity.
Solution Approach 2:
The foldable conveyor structure serves dual purposes: it performs the material transport function while simultaneously acting as the mounting platform for load measurement sensors. This multi-functionality eliminates the need for separate sensing apparatus, reducing overall system complexity while enabling material tracking.
3Measurement precision
If strain gauges are installed on the foldable conveyor sections, then the measurement precision for material tracking is improved, but the device complexity increases
Solution Approach 1:
The conveyor belt structure itself becomes the sensing element by integrating strain gauges directly into the belt or its rigid support structure. This self-service approach means the conveyor's own mechanical deformation under load is directly measured, eliminating the need for separate measurement apparatus and reducing installation complexity.
Solution Approach 2:
The patent replaces complex mechanical force measurement systems with electrical strain gauge sensors that directly measure strain on the conveyor structure. This substitution provides higher measurement precision with simpler installation and operation compared to traditional mechanical load cells or hydraulic measurement systems.
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 enables precise tracking of material removal, improving operational efficiency and enabling accurate monitoring of material delivered to haul vehicles, enhancing job site management and material accounting.
Implementation Method 1
sensing, via a sensor positioned on the milling machine, a value indicative of a force acting on the second section
Implementation Method 2
using sensors like pressure sensors and strain gauges to determine the amount of milled material
Data Source
AI summary
A milling machine includes a cutting rotor, a foldable conveyor, a sensor, and a controller. The cutting rotor is configured to mill material beneath the milling machine. The foldable conveyor is configured to receive and dispose the milled material and includes a first section and a second section foldable with respect to the first section at a fold structure. The sensor is positioned on the milling machine and configured to sense a value indicative of a force acting on the second section. The controller is configured to determine an amount of the milled material within the second section of the foldable conveyor using the value indicative of the force.