Milling Machine Controller for Level Surface Transition
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Solution Overview
Problem
Existing soil tillage machines leave uneven surfaces due to the inability to observe and manage the milling process, resulting in depressions and accumulations of mixed material when the milling drum is raised, requiring manual smoothing and interrupting the milling process.
Innovation Solution
A controller coordinates the milling depth and movement of the milling device to smoothly transition out of the ground, filling depressions with mixed material by synchronizing the lifting movement with the travel trajectory, ensuring a level surface without significant unevenness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the milling drum is raised to be out of engagement with the ground to move to the next lane or location, then the milling process can be interrupted and the machine can be repositioned, but a depression remains in the worked soil surface that requires manual smoothing and the process must be interrupted
Solution Approach 1:
The controller automatically performs the drum lifting action in advance before the operator needs to reposition the machine. By coordinating the drum lift with the travel movement along a predetermined trajectory, the system prepares the milling device for transition, eliminating the need for manual intervention and maintaining process continuity.
Solution Approach 2:
The system uses its own mixed material to fill the depression created during drum retraction. The mixing chamber material is automatically conveyed forward to fill the void, allowing the machine to self-correct the surface unevenness without external intervention, thereby maintaining productivity during repositioning.
2Loss of time
If the milling drum is raised quickly to reposition the machine, then the repositioning time is reduced, but a deep depression is created that requires significant manual smoothing work
Solution Approach 1:
The controller executes a predetermined trajectory that coordinates the drum lifting speed and position in advance. This pre-planned motion path ensures the drum is raised at an optimal rate that minimizes depression formation while maintaining efficient repositioning, eliminating the need for slow, careful manual operation.
Solution Approach 2:
The system uses sensors to detect the drum position, travel distance, and mixed material volume in real-time. This feedback information is continuously fed to the controller, which adjusts the drum lifting rate and mixed material conveyance to maintain surface levelness throughout the repositioning process, preventing excessive depression formation.
3Manufacturing precision
If the operator manually controls the milling drum height during repositioning, then the surface levelness can be maintained, but the operator cannot concentrate on driving and steering and the process is more complex
Solution Approach 1:
The system automatically manages the drum height control function using integrated sensors and controllers. The drum positioning system self-regulates based on predetermined trajectories and real-time feedback, eliminating the need for manual operator intervention in height control while maintaining surface levelness precision.
Solution Approach 2:
The controller merges multiple functions into a single automated system: drum height control, travel trajectory management, and mixed material conveyance timing. By combining these functions, the system eliminates the need for separate manual control operations, reducing operator workload while maintaining manufacturing precision through coordinated automated control.
4Manufacturing precision
If the milling process is interrupted for manual smoothing of depressions, then surface levelness can be restored, but productivity is reduced and the process requires additional equipment
Solution Approach 1:
The system merges the milling function with the surface leveling function into a single integrated process. The mixed material from the mixing chamber is automatically conveyed forward during drum retraction to fill depressions, combining material processing and surface restoration in one operation, thereby maintaining productivity while ensuring surface levelness.
Solution Approach 2:
The automated conveyance of mixed material to fill depressions occurs continuously during the drum retraction process, rather than requiring a separate manual smoothing step. This continuous action eliminates process interruptions and maintains milling productivity while ensuring surface levelness is restored automatically.
Data Source
Figure 1
Figure 2~4
AI summary
In a soil cultivation machine (1) for milling soils (2) or traffic areas, comprising a chassis (4) and a machine frame (6), a milling unit (8) rotating transversely to the direction of travel of the machine frame (6), a hood (10) enclosing the milling unit (8) and attached or suspended from the machine frame (6), which forms a mixing chamber (12) for the mixture (16) between the milling unit (8) and the hood (10), and a height adjustment device (20) for adjusting the milling depth of the milling unit (8), wherein the hood (10) enclosing the milling unit (8) has a pivotable hood flap (14, 15) at its front and/or rear end in the direction of travel, which closes off the mixing chamber (12) of the hood (10) from the soil surface (3) of the soil (2), a control (18) is provided for ending the milling operation and for adjusting the milling depth of the milling unit. (8) when moving forward or backward simultaneously_(5,7) controls along a predetermined path curve (24), whereby the milling device (8) can be extended into the upper position (9) out of contact with the ground, without leaving a depression in the worked soil surface (3) resulting from the extension of the milling device (8).