Hydraulic Power Unit Fullness Detection for Automated Compactors
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Solution Overview
Problem
Existing compactor systems face inefficiencies in monitoring fullness and scheduling pickups, leading to unnecessary hauls and high operational costs, with existing sensors being unsuitable or too expensive for widespread adoption.
Innovation Solution
A hydraulic power unit with integrated sensors and control systems, including a CAN controller, hydraulic manifold, and current draw monitoring, to accurately determine compactor fullness and automate pickup requests, while providing real-time data access and alerts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional scheduled pickup and maintenance is used for compactors, then routine service can be provided, but significant waste occurs as containers are hauled regardless of actual fullness
Solution Approach 1:
The system continuously monitors compactor fullness using pressure sensors and provides real-time feedback to the control system. When the sensor detects that the compactor is not full, the system automatically notifies the dispatch center to delay pickup, preventing unnecessary hauling of partially full containers and reducing waste.
Solution Approach 2:
The compactor system performs self-monitoring of its own fullness status through integrated pressure sensors and control systems. The container autonomously communicates its status to the dispatch center without requiring manual inspection or estimation, enabling the system to self-regulate pickup scheduling based on actual conditions.
2Productivity
If on-demand pickup based on pressure monitoring is implemented, then pickup efficiency improves, but staff time and operational complexity increase
Solution Approach 1:
The compactor system performs self-monitoring of its own fullness status through integrated pressure sensors and control systems. The container autonomously communicates its status to the dispatch center without requiring manual inspection or estimation, enabling the system to self-regulate pickup scheduling based on actual conditions.
Solution Approach 2:
The system replaces manual pressure monitoring and decision-making by staff with an automated electronic control system. The control system automatically interprets sensor data, determines fullness status, and communicates with the dispatch center, eliminating the need for staff to manually monitor pressure gauges and make pickup decisions.
3Extent of automation
If existing fullness sensors are used in compactors, then automation is achieved, but the sensors are unsuitable or too expensive for widespread adoption
Solution Approach 1:
The system employs cost-effective pressure sensors that can be easily manufactured and installed in compactors. These sensors are designed to be economical enough for widespread deployment across numerous containers, replacing expensive or complex sensing systems with simpler, more affordable technology that maintains adequate performance for determining compactor fullness.
Solution Approach 2:
The system changes the measurement parameter from complex volumetric or weight-based sensing to simpler pressure-based detection. By monitoring pressure changes in the hydraulic system that correlate with compactor fullness, the system achieves automation using inexpensive pressure sensors rather than costly specialized fullness sensors.
4Reliability
If routine scheduled pickups are performed, then service coverage is maintained, but haul frequency increases unnecessarily leading to higher operational costs
Solution Approach 1:
The system continuously monitors compactor fullness using pressure sensors and provides real-time feedback to the control system. When the sensor detects that the compactor is not full, the system automatically notifies the dispatch center to delay pickup, preventing unnecessary hauling of partially full containers and reducing waste.
Solution Approach 2:
The pickup schedule transitions from static and predetermined to dynamic and condition-based. The system continuously adjusts pickup timing based on real-time compactor fullness status, allowing pickups to be scheduled only when actually needed rather than following rigid predetermined schedules, thereby optimizing resource utilization.
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
Reduces waste disposal costs by optimizing haul frequency, minimizes false full indications, and offers a cost-effective solution for compactor automation with immediate ROI, compatible with existing systems.
Implementation Method 1
an electric motor on the mounting plate
Implementation Method 2
a hydraulic pump directly coupled to the motor
Implementation Method 3
the hydraulic power unit measures the current draw by the electric motor and wherein a signal level associated with a measure of the current draw is fed to the CAN control system
Data Source
AI summary
A hydraulic power unit for full compactor automation comprises a housing with a support frame, electrical control cabinet and plate cover; a reservoir; an electric motor on the frame; a hydraulic pump directly coupled to the motor; a CAN control system including a CAN controller, a gateway and antennae mounted to the housing and wherein the unit measures the current draw by the motor with a current transformer and wherein a signal level from the current transformer is fed to the CAN controller whereby decisions about the compactor's fullness are based on this signal level; an Integrated Circuit Hydraulic Manifold on the mounting plate including at least one Directional Control Valve, a Relief Valve, a Hydraulic Filter and a Check Valve; and an electronic entry PIN pad device on the electrical control cabinet allowing users to enter a personal identification number and operational commands.