Loader Cycle Counter Automating Aggregate Load Tracking
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Solution Overview
Problem
Current methods for tracking aggregate loads in ground engaging vehicles, such as loaders, are inefficient and prone to errors due to manual operation of mechanical palm counters and the need for operators to manually manage multiple aggregates.
Innovation Solution
A cycle counter system integrated with a loading machine, featuring weight sensors, an operator-activated control, and a processing circuit that automates the tracking of loads by producing control signals and adding weight values based on operator inputs, eliminating the need for manual counters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual palm counters are used to track aggregate loads, then the operator can track multiple aggregate types, but the operation becomes complex and error-prone requiring manual marking and selection for each aggregate
Solution Approach 1:
The patent replaces manual mechanical palm counters with an automated electronic cycle counter system. The system uses a processor, display, and control circuitry to automatically track aggregate loads, eliminating the need for manual marking and selection operations. The electronic system provides automated counting and tracking functionality that reduces operational complexity while maintaining the ability to track multiple aggregate types.
Solution Approach 2:
The cycle counter system performs self-tracking and self-counting functionality. The system automatically monitors and records aggregate load information without requiring continuous manual intervention. The processor automatically updates counts, manages multiple aggregate types, and provides feedback through the display, allowing the system to serve itself in the tracking process.
2Adaptability or versatility
If multiple palm counters are mounted in the cab to track different aggregates, then each aggregate can be tracked separately, but the device complexity increases and occupies cab space
Solution Approach 1:
The patent merges the functionality of multiple separate palm counters into a single integrated cycle counter system. The system combines tracking for multiple aggregate types within one unified device that includes a single display screen and centralized control mechanism. This consolidation reduces the number of separate counters needed while maintaining the capability to track different aggregate types separately.
Solution Approach 2:
The cycle counter system is designed as a universal device that can track multiple aggregate types through a single unit. The system uses programmable memory and control logic to manage different aggregate identifiers and counting operations within one device, eliminating the need for multiple specialized counters and reducing overall system complexity.
3Measurement precision
If the operator manually increments palm counters for each bucket load, then accurate tracking is achieved, but the operator efficiency decreases and time is lost
Solution Approach 1:
The patent replaces manual counting operations with an automated electronic system. The cycle counter uses a processor and control circuitry to automatically increment counts for each bucket load without requiring operator intervention. The system maintains accurate tracking by electronically recording each load event, providing both high precision and improved productivity by eliminating manual counting time.
4Measurement precision
If the operator uses remote add and remote clear switches to manage truck weight, then weight tracking is possible, but the operation becomes tedious and error-prone requiring repeated manual inputs
Solution Approach 1:
The patent replaces manual weight management operations with an automated electronic system. The cycle counter system automatically handles weight tracking and truck management functions through programmed logic, eliminating the need for repeated manual pressing of remote add and clear switches. The system maintains accurate weight tracking while significantly reducing operational complexity and error potential.
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
The system enhances efficiency and reduces errors by automating load tracking, allowing operators to focus on loading while providing accurate data for inventory management and billing, and can transmit data for further processing.
Implementation Method 1
The at least one weight sensor produces a weight signal relating to a measured weight of a weight lifted by the loading machine
Data Source
AI summary
A cycle counter system for use with a loading machine having a loading bucket. The cycle counter system includes at least one weight sensor, an operator activated control and a processing circuit. The at least one weight sensor produces a weight signal relating to a measured weight of a weight lifted by the loading machine. The operator activated control in the loading machine selectively produces at least one control signal. The processing circuit receives the control signal and the weight signal. The measured weight is added to a selected of a plurality of weight values dependent on the at least one control signal.