Milling Machine Lifting Column Load Detection for Kick-back Prevention
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Solution Overview
Problem
Milling machines face challenges in anticipating and preventing kick-back events and loss of traction during operations, leading to potential loss of steering or braking control and machine damage, as existing systems can only react after a kick-back event occurs and are prone to false signals.
Innovation Solution
A milling machine system equipped with a load cell sensor mounted on the lifting column to detect when it is not supporting a predetermined portion of the machine's weight, triggering a controller to automatically slow or stop the drive assembly and milling drum to prevent kick-back events and traction loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a milling machine operates without a load cell sensor on the lifting column, then the device complexity is reduced, but the reliability of preventing kick-back events and loss of traction deteriorates
Solution Approach 1:
The load cell sensor detects loss of traction condition before it leads to kick-back events or loss of steering control. The system takes preliminary action by slowing or stopping the drive assembly when the lifting column load falls below a threshold, preventing the harmful effect from occurring in the first place.
Solution Approach 2:
The load cell sensor provides continuous feedback on the lifting column load to the controller. This feedback loop enables the system to automatically adjust drive assembly operation based on real-time load conditions, improving reliability without requiring complex additional hardware.
2Loss of time
If existing kick-back prevention systems are used that only react after a kick-back event occurs, then the device complexity is reduced, but the loss of time in responding to traction loss increases
Solution Approach 1:
The system performs preliminary detection and response by monitoring lifting column load continuously. When load falls below the threshold indicating impending traction loss, the system slows or stops the drive assembly before a kick-back event occurs, eliminating the time loss associated with reactive systems.
3Measurement precision
If the load cell sensor is mounted to rotate or move with the frame during lifting column operation, then the ease of manufacture is improved, but the measurement precision of lifting column support force deteriorates
Solution Approach 1:
The sensor mounting bracket acts as an intermediary element that decouples the load cell sensor from direct movement with the frame. The bracket is rigidly attached to the frame while allowing the lifting column to move independently, ensuring the sensor maintains a consistent reference frame for accurate load measurement while still being manufacturable.
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 effectively anticipates and prevents kick-back events and traction loss, maintaining control and safety by automatically adjusting the milling machine's operations, reducing the risk of machine damage and operator danger.
Implementation Method 1
A load cell sensor mounted to the lifting column is adapted to determine if the lifting column is not supporting at least a predetermined portion of the weight of the milling machine
Data Source
AI summary
A milling machine includes a primary drum drive assembly for its milling drum, and a ground-engaging drive assembly for driving the milling machine along a roadway. A lifting column is attached between the frame and the ground-engaging drive assembly. The lifting column includes a linear actuator which can raise and lower the frame of the machine with respect to the roadway. A sensor mounted to the lifting column is adapted to determine if the lifting column is not supporting at least a predetermined portion of the weight of the milling machine. A controller is operatively attached to the drive assemblies and to the sensor, and is adapted to receive from the sensor a signal indicating that the lifting column is not supporting the predetermined portion of the weight of the milling machine. Upon receipt of such signal, the controller will automatically control certain machine functions.