Conveyor Speed Limiter for Cold Planer Secondary Belt
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Solution Overview
Problem
The secondary conveyor on cold planers often runs unnecessarily when not in use or without material, leading to fuel wastage and increased wear and tear on conveyor components.
Innovation Solution
A sensor system that detects the load on the secondary conveyor, sending information to a controller to adjust its speed based on the material load, allowing it to slow down or stop during unloaded times and return to normal speed when material is present.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the secondary conveyor runs continuously to maintain readiness for material transport, then the conveyor system is always prepared to receive and transport material, but fuel consumption increases and wear and tear on conveyor components increases
Solution Approach 1:
The conveyor system transitions from static continuous operation to dynamic variable speed operation. The controller adjusts the secondary conveyor speed based on real-time material presence detection, allowing the system to optimize between readiness and energy consumption by varying operational parameters rather than maintaining fixed continuous operation.
Solution Approach 2:
The system implements feedback control where the sensor detects material presence on the secondary conveyor and provides this information to the controller, which then adjusts conveyor speed accordingly. This closed-loop feedback mechanism enables the system to respond to actual operational conditions, reducing energy waste when material is absent while maintaining readiness when material is present.
2Reliability
If the secondary conveyor runs continuously to maintain readiness for material transport, then the conveyor system is always prepared to receive and transport material, but wear and tear on conveyor components increases
Solution Approach 1:
The system transitions from static continuous operation to dynamic variable speed operation. The controller adjusts the secondary conveyor speed based on real-time material presence detection, allowing the system to optimize between readiness and energy consumption by varying operational parameters rather than maintaining fixed continuous operation.
Solution Approach 2:
The system implements feedback control where the sensor detects material presence on the secondary conveyor and provides this information to the controller, which then adjusts conveyor speed accordingly. This closed-loop feedback mechanism enables the system to respond to actual operational conditions, reducing energy waste when material is absent while maintaining readiness when material is present.
3Loss of energy
If the secondary conveyor speed is reduced when unloaded to save fuel and reduce wear, then energy consumption decreases and component life extends, but the conveyor may not be ready to receive material promptly
Solution Approach 1:
The system transitions from static continuous operation to dynamic variable speed operation. The controller adjusts the secondary conveyor speed based on real-time material presence detection, allowing the system to optimize between readiness and energy consumption by varying operational parameters rather than maintaining fixed continuous operation.
Solution Approach 2:
The system implements feedback control where the sensor detects material presence on the secondary conveyor and provides this information to the controller, which then adjusts conveyor speed accordingly. This closed-loop feedback mechanism enables the system to respond to actual operational conditions, reducing energy waste when material is absent while maintaining readiness when material is present.
Data Source
AI summary
A cold planer can include a frame; a milling assembly including a drum housing and a cutting rotor located within the drum housing, the drum housing including a discharge port; a primary conveyor coupled to the frame, wherein the primary conveyor is positioned near the discharge port so as to receive material through the discharge port; a secondary conveyor positioned to receive material off an end of the primary conveyor; a sensor associated with the secondary conveyor to sense a load on the secondary conveyor; and a controller configured to receive information from the sensor regarding the load and to control a speed of the secondary conveyor based on the information.