Dump Cycle Counting via Controller Command State
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Solution Overview
Problem
Existing dump cycle counting systems are unreliable due to the need for sensors, which add complexity and cost, and can be susceptible to fraudulent recording, making it difficult to accurately track the number of loads carried by hauling vehicles.
Innovation Solution
A dump cycle counting system that monitors the command state of the dump control device and controller, recording a dump cycle only when the vehicle exceeds a predetermined ground speed and maintains a dump state for a specified time, eliminating the need for sensors and reducing the potential for fraudulent recording.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If sensors are used to monitor current level for determining dump cycles, then automatic monitoring capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the monitoring function from physical sensors and relocates it to the existing controller by monitoring the command state of the dump control device. This eliminates the need for separate sensors while maintaining automatic monitoring capability, as the controller already processes dump control signals and can detect when a dump cycle is initiated and completed.
Solution Approach 2:
The controller is given the additional function of counting dump cycles by monitoring its own command state, making it a multi-functional device. Instead of adding specialized sensors, the existing controller performs both its primary control function and the secondary counting function, reducing overall system complexity.
2Extent of automation
If sensors are installed to monitor dump cycles, then automatic counting is improved, but system cost increases
Solution Approach 1:
The patent removes the expensive sensor component from the system and extracts the monitoring capability to the existing controller. By utilizing the controller's existing processing ability to monitor command states, the system achieves automatic counting without the additional cost of sensors, wiring, and installation.
Solution Approach 2:
The controller monitors its own command state to determine when dump cycles occur, making the system self-monitoring. This self-service approach eliminates the need for external sensors and reduces system cost while maintaining automatic counting functionality.
3Measurement precision
If contact sensors are used to detect dump body position, then dump cycle recording is improved, but susceptibility to fraudulent recording increases
Solution Approach 1:
The patent uses the command state of the dump control device as an intermediary to detect dump cycles, rather than directly monitoring physical sensor signals. By monitoring when the controller receives and processes a dump command, the system creates a more reliable record that is harder to manipulate, as it ties the count to the actual control system activation rather than just physical position changes.
4Extent of automation
If dump body position sensors are used, then automatic dump cycle detection is improved, but ease of retrofitting decreases
Solution Approach 1:
The patent makes the existing controller multi-functional by adding dump cycle counting capability to its existing dump control function. Since the controller is already present in modern equipment and processes dump commands, adding the counting function requires only software or logic modifications rather than physical sensor installation, greatly facilitating retrofitting.
Solution Approach 2:
The patent extracts the counting function from separate sensor hardware and places it within the existing controller software or logic. This eliminates the need for additional physical components during retrofitting, reducing installation complexity and cost while maintaining automatic detection capability.
Data Source
AI summary
A dump cycle counting system is provided for a work machine. The system may include a payload carrier configured to contain a payload of material and a dump actuator configured to effectuate dumping of the payload out of the payload carrier. The system may also include a controller configured to control actuation of the dump actuator and a dump control device operatively coupled to the controller. The system may further include a load counter configured to record at least one dump cycle based on a command state of at least one of the dump control device and the controller.