Loading Tool Mass Control via Payload Volume Sensing
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Solution Overview
Problem
Existing methods for determining the mass of a payload during the operation of a loading tool are complex and prone to errors, requiring manual estimation which can lead to inefficient and inaccurate payload handling.
Innovation Solution
A method that uses calibration data to determine the mass of a payload by recording its volume using sensors, allowing for precise mass calculation and automatic control of the loading tool to ensure only the desired target mass is picked up, thereby relieving the operator and preventing over or underloading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual estimation methods are used to determine payload mass, then the operation remains simple, but the measurement precision and reliability deteriorate
Solution Approach 1:
The patent replaces manual mechanical estimation with an automated control system that uses sensors (optical, radar, or weight sensors) to detect payload volume or weight, combined with calibration data stored in a control unit. This substitution of mechanical/manual methods with sensor-based automation directly improves measurement precision while managing system complexity through electronic rather than mechanical means.
Solution Approach 2:
The patent implements feedback control by continuously monitoring the actual payload mass through sensors and comparing it with the target mass stored in the control unit. The system adjusts the loading process based on this feedback, improving measurement precision and reliability while maintaining manageable complexity through standardized feedback loops.
2Reliability
If calibration data and sensors are introduced to determine payload mass automatically, then the reliability and precision improve, but the device complexity increases
Solution Approach 1:
The patent applies preliminary action by storing calibration data (relationship between payload volume/density and mass) in the control unit before the actual loading operation. This pre-stored calibration data enables reliable automatic mass determination during operation without requiring complex real-time calculations, thus improving reliability while limiting complexity increase to data storage rather than computational complexity.
Solution Approach 2:
The patent uses optical sensors, radar, or weight sensors to create a copy or measurement representation of the payload's physical characteristics (volume, density, or weight) rather than directly manipulating the payload itself. This copying approach improves reliability by enabling indirect but accurate measurement, while keeping the physical system relatively simple by using non-contact or auxiliary measurement methods.
3Productivity
If automatic control is implemented to pick up exact target mass, then the productivity and precision improve, but the device complexity increases
Solution Approach 1:
The patent implements feedback control by continuously monitoring the actual payload mass through sensors and comparing it with the target mass stored in the control unit. The system adjusts the loading process based on this feedback, improving productivity and precision while maintaining manageable complexity through standardized feedback loops.
Solution Approach 2:
The patent replaces manual mechanical estimation with an automated control system that uses sensors (optical, radar, or weight sensors) to detect payload volume or weight, combined with calibration data stored in a control unit. This substitution of mechanical/manual methods with sensor-based automation directly improves measurement precision while managing system complexity through electronic rather than mechanical means.
4Productivity
If manual mass estimation is used, then the operation remains simple, but the loss of time and productivity worsen due to inaccurate handling
Solution Approach 1:
The patent replaces manual mechanical estimation with an automated control system that uses sensors (optical, radar, or weight sensors) to detect payload volume or weight, combined with calibration data stored in a control unit. This substitution of mechanical/manual methods with sensor-based automation directly improves measurement precision while managing system complexity through electronic rather than mechanical means.
Solution Approach 2:
The patent implements feedback control by continuously monitoring the actual payload mass through sensors and comparing it with the target mass stored in the control unit. The system adjusts the loading process based on this feedback, improving productivity and precision while maintaining manageable complexity through standardized feedback loops.
Data Source
Figure 1~2
AI summary
The invention relates to a method for controlling a loading tool (16) arranged on a lifting device (12) of a machine (10), wherein the loading tool (16) picks up a payload (L) from a payload bar (St_1, St_2, St_3) during its operation, and wherein the mass (m_L) of the payload (L) is determined during operation. For this purpose, calibration data (K) are provided, which represent a ratio of the volume (V_L) of the payload (L) to the mass (m_L) of the payload (L). During the operation of the loading tool (16), the volume (V_L) of the payload (L) is measured. The mass (m_L) of the payload (L) can then be determined as a function of the measured volume (V_L) and the calibration data (K).