Earth Working Machine Parameter Control for Tool Wear Reduction
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Solution Overview
Problem
The continuous wear of earth working tools in road reconstruction and mining processes leads to inefficient operations, high maintenance costs, and frequent tool replacements due to subjective machine parameter settings that do not adequately consider wear rates, especially when dealing with varying material properties.
Innovation Solution
Implementing a method to optimize machine parameters based on sensed material properties, allowing for the minimization of tool wear by adjusting parameters such as milling depth, rotation speed, and engine output, thereby extending maintenance intervals and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If machine parameters are set to maximize working output, then productivity is improved, but wear on earth working tools increases
Solution Approach 1:
The system dynamically adjusts machine parameters (rotation speed, advance rate, milling depth) based on real-time material property sensing and wear state monitoring. By changing operational parameters according to actual conditions, the system optimizes the balance between productivity and wear, preventing excessive wear while maintaining efficient operation.
Solution Approach 2:
The invention implements a closed-loop feedback system where wear state is continuously monitored and fed back to adjust machine parameters. The control unit receives wear information from sensors and automatically modifies operational parameters to prevent excessive wear, creating a self-regulating system that balances output and tool life.
2Duration of action of moving object
If machine parameters are set to minimize wear, then tool life is extended, but working output decreases
Solution Approach 1:
The system transitions from static, subjective parameter setting to dynamic, objective parameter adjustment. Machine parameters are continuously adapted based on real-time sensing of material properties and wear state, allowing the system to optimize tool life without permanently sacrificing productivity. The dynamics enable flexible response to changing conditions.
Solution Approach 2:
By dynamically changing operational parameters based on actual wear state and material properties, the system prevents premature tool failure while maintaining high productivity during periods when tools are still effective. This eliminates the need to consistently operate at reduced parameters.
3Reliability
If frequent inspections of wear state are conducted, then tool replacement timing is optimized, but machine availability decreases
Solution Approach 1:
The system implements automated self-monitoring of wear state through integrated sensors and processing units. The machine performs its own wear assessment without requiring external inspection, eliminating the need for manual checks that cause downtime. The automated system continuously tracks wear and triggers replacement only when necessary.
Solution Approach 2:
Manual visual inspection is replaced by automated sensing systems (optical, acoustic, or electrical sensors) that continuously monitor wear state. This substitution eliminates the need for machine stoppage during inspection, as the sensing system operates during normal machine function, thereby maintaining availability while improving reliability of wear assessment.
4Ease of operation
If manual setting of machine parameters is used, then operation simplicity is maintained, but wear optimization is insufficient
Solution Approach 1:
The system performs automatic parameter optimization without requiring expert knowledge from the operator. The processing unit autonomously analyzes sensor data and determines optimal parameters, freeing the operator from complex decision-making while achieving superior wear optimization compared to manual setting.
Solution Approach 2:
The system automatically adjusts multiple machine parameters based on sensed material properties and wear state, achieving optimization that would be difficult or impossible through manual setting. The automated parameter changes respond dynamically to conditions without requiring operator intervention or expertise.
Data Source
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.