Milling Rotor Depth Control via Sonic and Camera Sensors
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Solution Overview
Problem
Milling machines face challenges in maintaining consistent rotor depth during operations due to changes in ground profile and material conditions, making it difficult for operators to monitor and adjust the depth effectively.
Innovation Solution
A milling method and system that utilize sensors, such as sonic and image sensors, to continuously monitor the rotor's cutting height and automatically adjust it to a target depth through a controller, allowing for real-time correction and maintenance of optimal working depth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual monitoring and adjustment of rotor depth is used, then the operator has direct control, but the depth control becomes cumbersome and may go unnoticed during operation
Solution Approach 1:
The system employs sensors (sonic, camera, or other depth sensors) to continuously monitor the actual rotor cutting depth and feeds this information back to a controller. The controller compares the measured depth with the target depth and automatically adjusts the rotor depth to maintain consistency, eliminating the need for manual monitoring while ensuring reliable depth control.
Solution Approach 2:
The milling machine performs self-adjustment of rotor depth through automated control systems. The machine monitors its own operating parameters and makes necessary adjustments without external intervention, improving both ease of operation and reliability by maintaining consistent depth control throughout the working operation.
2Reliability
If automatic sensor-based control is implemented, then depth consistency is improved, but device complexity increases
Solution Approach 1:
The patent replaces manual mechanical depth adjustment and monitoring with automated sensor-based detection and electronic control. Sensors (sonic, camera, or other types) detect rotor depth position, and an electronic controller automatically adjusts depth through actuators, eliminating the need for manual mechanical intervention while maintaining simple operational interfaces.
3Measurement precision
If continuous monitoring is performed, then depth accuracy is maintained, but energy consumption increases
Solution Approach 1:
Instead of continuous monitoring, the system performs depth measurements at periodic intervals or at key moments during the working operation. The controller monitors sensor data and only activates adjustment mechanisms when depth deviation exceeds predetermined thresholds, reducing energy consumption while maintaining adequate measurement precision for effective depth control.
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
Ensures consistent and accurate rotor depth control, improving operational efficiency and reducing the need for manual adjustments, thereby maintaining uniform working depth across varying conditions.
Implementation Method 1
A plurality of sonic sensors; and a controller configured to automatically control height of the rotor to adjust a rotor cutting height for the rotor to a target cutting height stored in memory and accessible by the controller responsive to a control input received at the operator control interface and based on data from the plurality of sonic sensors
Implementation Method 2
each of the sensors being one of a sonic sensor or a camera
Data Source
AI summary
A milling machine, system, and method for adjusting a rotor cutting height adjusts the rotor cutting height to a target cutting height responsive to a control input received at an operator control interface. One or more legs of the milling machine and/or a height of the rotor can be adjusted to adjust the rotor cutting height to the target cutting height. The rotor cutting height can be adjusted based on data from one or more sensors. Each sensor may be a sonic sensor or an image capturing sensor.