Loader Bucket Pitch Control for Precise Payload Weight
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Solution Overview
Problem
Current loader systems face challenges in accurately and efficiently loading a truck with a precise payload weight, often requiring manual trial and error, leading to time-consuming and wasteful processes, especially for less skilled operators, and resulting in overloading or underloading issues.
Innovation Solution
A method and system utilizing an electronic payload controller with a dump control algorithm that determines a dump control parameter based on a target load, allowing for the precise dumping of excess material from the loader bucket to achieve the desired truck payload weight, incorporating sensors and actuators to manage the bucket tilt and compensate for non-horizontal loading conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual trial and error weighing cycles are used to achieve target payload weight, then the truck can be loaded with desired material, but the process becomes time-consuming and wasteful
Solution Approach 1:
The system performs preliminary weighing of the bucket load before dumping into the truck. The payload control system measures the bucket payload and calculates the exact amount needed to reach the target truck weight, eliminating the need for time-consuming trial and error cycles after loading begins
Solution Approach 2:
The payload control system continuously monitors the truck's current weight and compares it to the target weight, providing real-time feedback to the operator. This feedback loop enables precise control of the loading process, allowing the operator to stop adding material exactly when the target weight is reached
2Productivity
If the entire bucket load is dumped into the truck on the final pass, then the loading process is simplified, but the truck may be overloaded or underloaded
Solution Approach 1:
The system intentionally loads the bucket with slightly more material than needed for the final pass, then uses the payload control system to calculate and control the precise portion to dump into the truck. This approach ensures the truck reaches the target weight accurately without requiring perfect bucket filling precision
3Ease of operation
If less skilled operators perform manual trial and error loading, then they can load the truck, but substantially more time is required and operator fatigue increases
Solution Approach 1:
The payload control system performs the complex calculations and decision-making automatically, telling the operator exactly how much material to load and when to stop. This self-service approach eliminates the need for operator expertise in estimating weights or judging when to stop loading, making the system equally easy to operate for any skill level
Data Source
AI summary
A method of loading a truck with material using a loader includes a step of determining a target load for a final pass. Material is loaded into a bucket of the loader in excess of the target load. Excess material is dumped from the bucket back to the pile in a controlled manner to arrive at a target load of reposed material in the bucket. The target load amount of the material in the bucket, which is less than a total amount of material originally loaded in the bucket is dumped into the truck by pitching the bucket. The bucket may be pitched to a determined pitch angle that is based upon the target load using an appropriate material curve stored on the loader. The pitch control algorithm can be calibrated by sensing the reposed weight of material in the bucket, and comparing that to an expected reposed weight, and then updating one of the material curves if there is a deviation.