Milling Machine Automatic Grade Control System
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Solution Overview
Problem
Conventional milling machines require manual adjustment of rear lifting columns, which is time-consuming and prone to errors, as operators rely on visual monitoring to maintain the desired cut depth during the milling process, lacking an automated system for precise control of the milling drum elevation.
Innovation Solution
A system featuring four elevation sensors and a controller that automatically adjusts the lifting columns to maintain the desired cut depth by providing continuous feedback and actuating the linear actuators, ensuring the milling drum remains at the correct elevation throughout the milling operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual adjustment of rear lifting columns is used, then the device complexity is reduced, but the manufacturing precision and productivity deteriorate due to time-consuming manual operations and operator errors
Solution Approach 1:
The system employs elevation sensors that continuously monitor the actual elevation of the milling drum and provide feedback signals to the controller. The controller compares the actual elevation with the desired elevation and automatically adjusts the lifting columns to maintain the desired cut depth, eliminating manual intervention and improving precision.
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated electro-hydraulic system. The controller receives sensor data and automatically actuates the hydraulic linear actuators within the lifting columns, substituting human operation with an automated control system that uses electrical signals and hydraulic actuation for precise elevation control.
2Device complexity
If manual adjustment of rear lifting columns is used, then the device complexity is reduced, but the productivity deteriorates due to time-consuming manual monitoring and adjustment operations
Solution Approach 1:
The continuous feedback loop from elevation sensors to the controller enables real-time automatic adjustment of the milling drum elevation, eliminating the need for operators to manually monitor and adjust settings during the milling operation, thereby significantly improving productivity.
Solution Approach 2:
The system performs self-adjustment of the lifting columns based on sensor feedback without requiring external manual intervention. The controller automatically commands the hydraulic actuators to maintain the desired cut depth, allowing the machine to service itself during operation and maximizing productivity.
3Device complexity
If visual monitoring by operators is used, then the device complexity is reduced, but the measurement precision deteriorates due to reliance on human visual assessment
Solution Approach 1:
The patent substitutes human visual monitoring with electronic elevation sensors that provide precise, objective measurements of the milling drum elevation. These sensors transmit accurate data to the controller, eliminating the imprecision and subjectivity inherent in manual visual assessment.
Solution Approach 2:
The elevation sensors provide continuous, real-time feedback on the actual drum elevation to the controller, enabling precise measurement and comparison with the desired elevation. This automated measurement system delivers superior precision compared to human visual monitoring.
Data Source
AI summary
A milling machine includes a milling assembly having a housing to which left and right end gates are attached, a controller, a right front lifting column, a left front lifting column and a rear lifting column. Elevation sensors are located at the front and rear of each of the end gates. The controller is operatively attached to the elevation sensors and to linear actuators within the lifting columns of the milling machine. The elevation sensor that is located at the front end of the right end gate will provide feedback to control the position of the right front lifting column, and the elevation sensor that is located at the front end of the left end gate will provide feedback to control the position of the left front lifting column. The elevation sensors that are located at the rear ends of the end gates are available, as selected by the operator, to provide feedback to control the positions of one of the right and left front lifting columns, as well as the rear lifting column.