Discharge Conveyor Alignment via Paver-Locating Sensor Scans
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Solution Overview
Problem
Current systems for controlling the discharge conveyor of material transfer vehicles during asphalt paving operations are cumbersome, requiring sensor targets on the paving machine and sensors on the conveyor, and necessitate precise tracking by the paving machine, which complicates alignment and coordination with the hopper, especially on curved roadways or intersections.
Innovation Solution
A system featuring a paver-locating sensor mounted on the material transfer vehicle that executes multiple non-contact sensor scans across the paving machine to maintain alignment of the discharge conveyor with the hopper, using a controller connected to steering and elevation control systems, without requiring sensor targets or modifications to the paving machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensor targets are mounted on the paving machine and sensors are mounted on the discharge conveyor, then alignment control can be achieved, but the device complexity increases and the ease of operation deteriorates due to cumbersome installation and coordination requirements
Solution Approach 1:
The patent removes the sensor target from the paving machine and eliminates the need for sensors on the discharge conveyor. Instead, it uses a camera mounted on the discharge conveyor to capture images of the hopper, processing the images to determine relative position and orientation. This extraction of the target from the paving machine simplifies the overall system while maintaining alignment control capability.
Solution Approach 2:
The patent replaces the mechanical/optical sensor-target system with an image-based detection system. A camera captures visual information of the hopper, and image processing algorithms extract position and orientation data. This substitution eliminates the need for physical sensor targets and complex sensor installations, reducing device complexity while achieving the same measurement function.
2Manufacturing precision
If the paving machine precisely tracks the material transfer vehicle, then alignment is maintained, but the ease of operation worsens due to stringent coordination requirements
Solution Approach 1:
Instead of requiring the paving machine to precisely track the material transfer vehicle, the patent inverts the approach: the camera on the discharge conveyor actively detects the hopper's position and orientation, and this information is used to control the discharge conveyor's alignment. This inversion shifts the active tracking function from the paving machine to the material transfer vehicle's discharge system, simplifying coordination requirements.
Solution Approach 2:
The patent implements a feedback control system where the camera continuously captures images of the hopper, image processing algorithms determine the relative position and orientation, and this feedback information is used to adjust the discharge conveyor's position and angle. This closed-loop feedback mechanism maintains alignment precision without requiring complex pre-coordination between vehicles.
3Measurement precision
If multiple sensor targets and sensors are installed on both vehicles, then alignment can be controlled, but the ease of manufacture deteriorates due to installation requirements
Solution Approach 1:
The patent extracts the target detection function from the paving machine entirely. Instead of mounting sensor targets on the paving machine, the camera on the discharge conveyor captures images of the hopper itself, which serves as the natural target. This eliminates the need for additional target installation on the paving machine, simplifying manufacturing and installation.
Solution Approach 2:
The patent makes the hopper serve dual functions: it is both the structural component of the paving machine and the visual target for alignment detection. The hopper's existing structure and features are utilized as the target, eliminating the need for separate target installation. This self-service approach simplifies manufacturing while maintaining measurement precision.
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 automatic and precise alignment of the discharge conveyor with the hopper, allowing for continuous operation without stopping, improved material distribution, and reduced heat loss, while avoiding the need for sensor targets or additional machinery modifications.
Implementation Method 1
a paver-locating sensor mounted on the material transfer vehicle that executes multiple non-contact sensor scans across the paving machine
Data Source
AI summary
A material transfer vehicle has a discharge conveyor with a discharge chute mounted thereon. A controller is operatively connected to the elevation control system and the steering control system for the discharge conveyor. The controller is adapted to communicate with the elevation control system for the discharge conveyor to adjust the elevation of the discharge conveyor. The controller is also adapted to communicate with the steering control system for the discharge conveyor so that the angular orientation of the discharge conveyor with respect to the longitudinal axis of the material transfer vehicle may be adjusted. A paver-locating sensor is operatively connected to the controller, and is located and adapted to execute multiple non-contact sensor scan passes across the front end of the paving machine to determine the distance and orientation of the paving machine with respect to the paver-locating sensor and to communicate this information.