Milling Rotor Load Sensing for Active Cut Width Detection

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Solution Overview

Problem

Existing cold planer milling machines lack an effective method to determine the active cut width of the cutting rotor, which is crucial for estimating the volume of material milled, as they often operate in either partial or full width cuts without clear differentiation.

Innovation Solution

The implementation of a plurality of load detection sensors along the width of the cutting rotor, coupled with a controller to determine the active cut width based on load information from these sensors, allowing for the identification of engaged and disengaged cutting bits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If multiple load detection sensors are installed along the cutting rotor width, then measurement precision of active cut width is improved, but device complexity increases

Engineering Contradiction:

Improveactive cut width measurementVSAvoidsensor system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The cutting rotor width is divided into multiple measurement zones, with individual load detection sensors positioned at different radial locations. Each sensor monitors a specific segment of the cut width, allowing the controller to determine which portions are actively engaged with material. This segmentation enables precise mapping of active cut width without requiring a single complex measurement system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The load detection sensors serve as intermediary devices that indirectly measure active cut width by detecting load conditions on cutting bits. Rather than directly measuring the geometric width of the cut, the sensors detect mechanical load signals that correlate with material engagement, providing measurement data to the controller for calculation of active cut width.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Area of stationary object

If load detection sensors are positioned across the entire width of the cutting rotor, then measurement coverage is improved, but manufacturing cost increases

Engineering Contradiction:

Improvesensor coverage areaVSAvoidmanufacturing cost

Core Design Contradiction:

Area of stationary objectVSEase of manufacture

Solution Approach 1:

Rather than installing sensors across the entire theoretical width of the cutting rotor, the system uses a plurality of sensors positioned at key radial locations that provide sufficient measurement coverage to determine active cut width. The sensor array covers enough area to identify engaged and disengaged cutting bits, achieving adequate measurement coverage without the excessive cost of complete width coverage.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS11441884B2Cut width determination for a milling machine via rotor loads

Publication Date: 2022.09.13 CATERPILLAR PAVING PROD INC

AI summary

A milling machine can include a frame; a milling assembly coupled to the frame and including a drum housing and a cutting rotor located within the drum housing; a plurality of load detection sensors extending along a width of the cutting rotor; and a controller operatively coupled to each of the plurality of load detector sensors and configured to determine an active cut width of the cutting rotor based on load information received from the plurality of load detector sensors.