Dump Body Weight Calibration Using Actuator-Simulated Load

Solution Overview

Problem

Weighing systems in machines with dump bodies face calibration challenges due to factors like machine modifications, damage, and harsh terrain, leading to inaccurate weight computations of materials.

Innovation Solution

A method and system that involve acquiring initial values from strain sensors in an unladen state, simulating forces using an actuator to mimic laden state conditions, and recalibrating the process using these values to improve accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If weighing systems are used to compute material weight in dump bodies, then weight measurement capability is provided, but measurement precision deteriorates due to machine modifications, damage, and harsh terrain affecting sensor readings

Engineering Contradiction:

Improveweight measurement precisionVSAvoidsensor reading reliability

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The system performs preliminary calibration by acquiring sensor values in both unladen and laden states to establish a baseline relationship between sensor readings and actual weight. This preliminary action creates a reference model that compensates for subsequent changes in machine conditions, terrain effects, and sensor drift, thereby maintaining measurement precision despite deteriorating reliability conditions

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements feedback by continuously monitoring sensor readings and comparing them against the calibrated baseline. When deviations occur due to machine modifications, damage, or terrain variations, the system uses the stored calibration data to correct the weight computation, ensuring that measurement precision is maintained even as sensor reliability deteriorates over time

Inventive Principle:

Principle #23Feedback

2Measurement precision

If strain sensors are used to detect weight values, then weight detection capability is provided, but measurement precision deteriorates due to sensor damage and environmental harshness

Engineering Contradiction:

Improveweight detection precisionVSAvoidsensor damage and terrain harshness

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The system performs preliminary calibration by acquiring sensor values in both unladen and laden states to establish a baseline relationship between sensor readings and actual weight. This preliminary action creates a reference model that compensates for subsequent changes in machine conditions, terrain effects, and sensor drift, thereby maintaining measurement precision despite deteriorating reliability conditions

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements feedback by continuously monitoring sensor readings and comparing them against the calibrated baseline. When deviations occur due to machine modifications, damage, or terrain variations, the system uses the stored calibration data to correct the weight computation, ensuring that measurement precision is maintained even as sensor reliability deteriorates over time

Inventive Principle:

Principle #23Feedback

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 approach enhances the accuracy of weight computation by accounting for changes and wear, ensuring precise material weight measurement despite operational and environmental factors.

Implementation Method 1

weighing systems generally include sensors (e.g., strain sensors) that may detect values (e.g., strain values or voltages) corresponding to a receipt of load into the dump body

Methodology Applied

Scientific EffectStrain sensing: Piezoresistive Effect

Implementation Method 2

activating, by the controller, an actuator to push the dump body against the strain sensors to simulate one or more forces exertable by one or more payloads

Methodology Applied

Scientific EffectMechanical force: Mechanical Force

Data Source

PatentUS20230324215A1System and method for calibrating process to compute weight of material in dump bodies

Publication Date: 2023.10.12 CATERPILLAR INC

AI summary

A method for calibrating a process by which a weight of a material in a dump body of a machine is computed. The method includes acquiring first values correspondingly from one or more strain sensors in an unladen state of the dump body; activating an actuator to push the dump body against the strain sensors to simulate one or more forces exertable by one or more payloads in a laden state of the dump body; and acquiring second values correspondingly from the strain sensors when the actuator is activated to simulate the forces. Further, the method includes using the first values and the second values to calibrate the process.