Dynamic Payload Control System for Mining Tire Wear
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Solution Overview
Problem
Existing payload control systems for mobile machines, like those in the mining industry, face challenges in balancing tire heat generation and productivity, as they either lead to excessive tire wear or create bottlenecks by limiting machine speed.
Innovation Solution
A payload control system that includes force sensors to measure the force transmitted through traction devices, speed sensors to measure machine speed, and a controller that adjusts the weight limit based on these measurements to maintain optimal tire heat generation while allowing high travel speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If machine speed is limited to reduce tire heat generation, then tire wear is reduced, but productivity decreases due to bottlenecks in multi-machine operations
Solution Approach 1:
The weight limit is made dynamic rather than static. The controller continuously adjusts the weight limit based on real-time measurements of force and speed using sensors, allowing the system to adapt to changing operating conditions. This enables speed to vary dynamically while managing tire heat generation, resolving the contradiction between maintaining productivity and reducing tire wear.
Solution Approach 2:
The system changes the parameter being controlled from speed (in prior art) to weight limit. By modifying the weight limit parameter based on measured force and speed, the system indirectly controls tire heat generation (TMPH) without directly limiting speed, thus maintaining productivity while protecting tires.
2Productivity
If machine speed is increased to maintain productivity, then productivity is maintained, but tire heat generation increases leading to accelerated wear and failure
Solution Approach 1:
The system implements feedback control by continuously measuring force and speed using sensors, comparing actual TMPH to the weight limit threshold, and adjusting the weight limit accordingly. This closed-loop feedback mechanism ensures that tire heat generation is managed while allowing speed to maintain productivity.
Solution Approach 2:
The system replaces direct mechanical speed limiting with a control system that uses sensors and a controller to adjust weight limits. This substitution allows indirect control of tire heat generation through weight management rather than direct speed control, maintaining productivity while reducing harmful thermal effects.
Data Source
AI summary
In one aspect, the present disclosure is directed to a payload control system for a machine having traction devices. The payload control system may have a force sensor configured to measure a force transmitted through the traction devices. The payload control system may also have a speed sensor configured to measure a speed of the machine. The payload control system may further have a controller in communication with the force sensor and the speed sensor. The controller may be configured to modify a weight limit of the machine based on the measured force and the measured speed.