Dump Bed Load Distribution Control for Material Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing systems for moving materials between machines, such as excavators and dump trucks, lack efficient methods for optimizing load distribution and unloading positions based on the type of material being moved.
Innovation Solution
A system comprising a first machine with a bucket and an operator interface, and a second machine with a dump bed and sensors, where controllers on both machines communicate to determine the load distribution and optimal unloading position based on the material type, allowing for precise placement of loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If material is moved using conventional systems without load distribution optimization, then the material transfer process is simple, but the stability and efficiency of material transfer deteriorates
Solution Approach 1:
The system implements feedback control by using sensors to measure the actual load distribution in the dump bed and comparing it with the target distribution. The controllers receive this feedback information and automatically adjust the bucket position and dumping timing to correct any deviations, thereby optimizing material transfer efficiency while maintaining system stability
Solution Approach 2:
The system enables self-service operation where the controllers autonomously determine optimal unloading positions and timing based on sensor data and pre-stored material characteristics. The operator interface automatically selects appropriate parameters based on the type of material being moved, reducing the need for manual intervention and improving transfer efficiency without requiring complex operator skills
2Stability of the object's composition
If load distribution is optimized based on material type, then the stability of material transfer is improved, but the complexity of control increases
Solution Approach 1:
The system performs preliminary action by pre-storing load distribution parameters and material characteristics in the controllers before the actual material transfer begins. When a specific material type is selected through the operator interface, the corresponding pre-configured parameters are automatically activated, enabling stable load distribution without requiring complex real-time calculations during operation
Solution Approach 2:
The system manages control complexity by changing parameters based on material type rather than adjusting individual control variables in real-time. The controller selects from pre-defined parameter sets corresponding to different material types (e.g., granular, cohesive, heavy), which simplifies the control logic while maintaining optimal load distribution stability for each material category
3Manufacturing precision
If optimal unloading position is determined based on load distribution, then the precision of load placement is improved, but the time required for determination increases
Solution Approach 1:
The system resolves the time-precision trade-off by performing preliminary determination of unloading positions based on pre-stored material characteristics and target load distribution patterns. The controllers calculate optimal positions in advance for each material type, allowing precise load placement without requiring time-consuming real-time computations during the actual dumping operation
Solution Approach 2:
The system applies local quality by determining specific unloading positions tailored to each material type's characteristics. Instead of using a generic dumping approach, the controller identifies precise locations in the dump bed where material should be deposited based on the specific properties of the material being moved, achieving high placement precision while maintaining efficient operation through pre-configured position data
4Measurement precision
If sensor-based load measurement is implemented, then the accuracy of load distribution determination is improved, but the device complexity increases
Solution Approach 1:
The sensor system implements self-service by automatically measuring load distribution and feeding this data directly to the controllers without requiring manual measurement or complex external measurement systems. The sensors are integrated into the dump bed structure and work autonomously to provide accurate load information, improving measurement precision while keeping the overall system relatively simple through automated self-measurement
Data Source
AI summary
A method of moving material, using a first machine, from a first location to a second location, the second location being a dump bed of a second machine. The method includes determining, by a controller of the first machine, a type of a material to be moved, sending, by the controller of the first machine, the material type to a controller of the second machine, determining, by a controller of the second machine, a load distribution on the dump bed based on the material, determining, by the controller of the second machine, a first position of the dump bed at which a first dump should be unloaded from the first machine, and sending, by the controller of the second machine, an identification of the first position to the controller of the first machine.