Earth Working Machine Wear Control via Adaptive Parameter Settings

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Solution Overview

Problem

The continuous wear of earth working tools, such as milling bits, in road reconstruction and mineral deposit removal processes leads to inefficient operations, increased maintenance costs, and unpredictable wear rates due to subjective machine parameter settings and varying substrate properties, resulting in disrupted production and high replacement frequencies.

Innovation Solution

A method and system for an earth working machine that senses material properties and adjusts machine parameters to optimize wear, extending inspection intervals and reducing maintenance costs by setting parameters to minimize tool wear while maintaining efficient operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If machine parameters are set to maximize working output, then productivity is improved, but tool wear increases leading to more frequent replacements

Engineering Contradiction:

Improveworking outputVSAvoidtool replacement frequency

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The system dynamically adjusts machine parameters (rotor rotation speed, travel speed, milling depth) based on real-time sensor data about material properties and tool wear state. This allows optimization of the working parameters to balance productivity with tool wear reduction, extending tool life while maintaining efficient operation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system implements continuous feedback loops where sensors monitor tool wear state and material properties, and this information is used to automatically adjust machine parameters. The feedback mechanism enables real-time optimization of the trade-off between working output and tool wear without requiring manual intervention or subjective judgment

Inventive Principle:

Principle #23Feedback

2Duration of action of stationary object

If machine parameters are set to minimize tool wear, then tool life is extended, but working output decreases

Engineering Contradiction:

Improvetool lifeVSAvoidworking output

Core Design Contradiction:

Duration of action of stationary objectVSProductivity

Solution Approach 1:

The system transitions from static, subjective parameter setting to dynamic, data-driven parameter adjustment. Machine parameters are continuously adapted based on real-time sensor feedback about tool wear and material properties, allowing the system to optimize the balance between tool life extension and maintaining productive working output

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system modifies machine operating parameters (rotation speed, travel speed, milling depth) based on quantified tool wear state and material characteristics. This enables flexible adjustment of parameters to extend tool life while minimizing the negative impact on working output through intelligent, real-time optimization

Inventive Principle:

Principle #35Parameter changes

3Reliability

If visual inspection of tool wear is performed frequently, then tool wear state is monitored, but production time is lost

Engineering Contradiction:

Improvewear state monitoringVSAvoidproduction time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system replaces manual visual inspection with automated sensor-based measurement systems. Sensors continuously monitor tool wear state without requiring machine stoppage or operator intervention, eliminating the trade-off between monitoring reliability and production time loss

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system implements self-monitoring capabilities where sensors automatically detect and report tool wear state without external intervention. The machine monitors its own tool condition continuously, providing reliable wear information without removing productive time from the operation

Inventive Principle:

Principle #25Self-service

4Ease of operation

If subjective machine parameter settings are used, then operation simplicity is maintained, but wear optimization is insufficient

Engineering Contradiction:

Improveparameter setting simplicityVSAvoidtool replacement frequency

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The system enables the machine to automatically determine and adjust optimal parameters based on sensor data about material properties and tool wear state. This self-parameterizing capability eliminates the need for subjective operator judgment while maintaining operational simplicity through automated decision-making

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system automatically modifies machine parameters based on quantified data about material properties and tool wear, replacing subjective parameter setting with objective, data-driven adjustment. This maintains ease of operation while significantly improving wear optimization through continuous, intelligent parameter adaptation

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS12398641B2Earth working machine and method for wear-optimized operation of an earth working machine

Publication Date: 2025.08.26 WIRTGEN GMBH

AI summary

The invention relates to an earth working machine and to a method for wear-optimized operation of such an earth working machine. Provision is made in this context that machine parameters with which the earth working machine is operated are adapted, in consideration of material properties of the substrate to be worked, in such a way that favorable wear behavior exists for the earth working tools being used.