Haulage Vehicle Hoist Cylinder Load Detection for Dumping Completion
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Solution Overview
Problem
Operators of large-sized dump trucks face challenges in precisely determining the completion of dumping work due to inadequate backward visibility from the cab and existing automatic control systems that do not account for the type of load being dumped, leading to uncertainties in completion time.
Innovation Solution
The implementation of a haulage vehicle with a controller and hydraulic system that uses differential pressure calculations and sensors to determine when the dumping is complete by analyzing the force orientation on the hoist cylinders, allowing for precise detection of the empty state of the vessel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automatic control is implemented to pull down the vessel after a set time, then productivity is improved, but measurement precision of dumping completion deteriorates
Solution Approach 1:
The system continuously monitors the load on the hoist cylinder during dumping and uses this feedback to detect when dumping is actually complete. The load detection unit measures the force on the hoist cylinder, and when the load becomes zero (indicating all material has been dumped), the system automatically pulls down the vessel. This replaces fixed-time control with real-time condition-based control.
Solution Approach 2:
The patent replaces mechanical/time-based control systems with sensor-based detection systems. Instead of using a timer or manual observation, the system uses load detection units (sensors) to electronically detect when the vessel is empty, enabling precise automatic control without mechanical intervention.
2Measurement precision
If the operator manually operates the control lever to tilt the vessel, then measurement precision of dumping completion is improved, but ease of operation deteriorates
Solution Approach 1:
The system enables automatic dumping operation where the vessel autonomously tilts and returns based on load detection. The operator simply needs to initiate the dumping sequence, and the system automatically monitors the load, detects completion, and returns the vessel to its initial position without requiring continuous manual control.
Solution Approach 2:
The load detection unit provides continuous feedback to the control unit, which automatically adjusts the vessel tilt angle and timing based on the actual dumping progress. This feedback loop eliminates the need for manual judgment and control, reducing operator workload while maintaining precise control over the dumping process.
3Ease of operation
If the operator relies on backward field of view to determine dumping completion, then ease of operation is maintained, but measurement precision deteriorates
Solution Approach 1:
The patent introduces an intermediary detection system (load detection unit and control unit) that indirectly measures dumping completion by monitoring the load on the hoist cylinder. This intermediary system provides accurate information about dumping status without requiring the operator to directly observe the vessel contents, solving the visibility problem while maintaining ease of operation.
Solution Approach 2:
The system replaces visual observation with electronic sensing. Instead of relying on the operator's line of sight to determine when dumping is complete, the load detection unit electronically senses when the vessel load reaches zero, providing accurate detection without any visual requirements.
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
Enables operators to accurately confirm the completion of dumping operations without visual inspection, improving efficiency and safety by ensuring that no residue is left in the vessel, and allowing for automated dumping processes.
Implementation Method 1
a load detection unit that detects a load on the hoist cylinder by a differential pressure in a hydraulic system for the hoist cylinder
Data Source
Figure 1~2
Figure 3A~3B
Figure 4
AI summary
An object of the present invention is to provide a haulage vehicle that enables precisely confirming that work for dumping a load is completed. The present invention is based upon a haulage vehicle provided with a vehicle frame (2), a vessel (7) tiltably mounted on the vehicle frame and a hoist cylinder (9) which is provided between the vehicle frame and the vessel and which tilts the vessel, and has a characteristic that a load detector (39A, 39B, 23a) that detects force that acts in an extended or a contracted direction of the hoist cylinder and an empty load determination unit (23b) that determines whether the vessel is empty on the basis of a detection signal from the load detector or not are provided.