Road Milling Sensor Switching for Continuous Depth Control
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Solution Overview
Problem
Existing grade control systems for construction machines, particularly road milling machines, lack advanced functionality for efficiently switching between sensor subsets to maintain accurate milling depth and profile control.
Innovation Solution
A method and system that utilizes a controller to prioritize sensor subsets based on a priority ranking, automatically selecting the most suitable subset to create a cross-sectional profile of the design surface by using available sensors, and adjusting milling depth accordingly, considering current or predicted positions and orientations of the milling drum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual sensor subset switching is used, then operator control is maintained, but automation level and operational efficiency deteriorate
Solution Approach 1:
The system performs sensor subset selection and switching automatically based on sensor status and milling conditions, without requiring operator intervention. The controller evaluates sensor availability and autonomously determines the optimal sensor subset to maintain milling operations.
Solution Approach 2:
The system pre-establishes priority rankings for multiple sensor subsets before switching is needed. When sensor failure occurs, the controller can immediately switch to the next highest priority subset without delay, as the ranking hierarchy was prepared in advance.
2Manufacturing precision
If sensor subset switching is delayed, then system simplicity is maintained, but milling precision and profile accuracy deteriorate
Solution Approach 1:
The system continuously monitors sensor operational status and automatically triggers switching when sensor failure is detected. This real-time feedback mechanism ensures milling precision is maintained by eliminating delays between sensor failure and subset switching.
Solution Approach 2:
Priority rankings for sensor subsets are established in advance, enabling the controller to immediately switch to the appropriate subset when needed, without time-consuming decision-making during critical milling operations.
3Reliability
If multiple sensor subsets are maintained with priority rankings, then adaptability to sensor failures is improved, but device complexity increases
Solution Approach 1:
The sensor system is divided into multiple discrete subsets, each with a defined priority ranking. This segmentation allows the system to methodically evaluate and switch between subsets based on sensor availability, improving reliability through structured redundancy.
Solution Approach 2:
The controller is designed to universally manage multiple sensor subsets through a single priority-ranking mechanism. This multi-functional approach allows the same control system to handle various sensor configurations and failure scenarios without requiring separate control logic for each case.
Data Source
AI summary
A construction machine uses a controller configured to determine a cross-sectional profile of a design surface at a selected position and orientation of a milling drum of the construction machine. The controller automatically determines a preferred sensor sub-set from a plurality of possible sensor sub-sets selected from a set of available sensors. The preferred sensor sub-set must be usable to create at least a portion of the cross-sectional profile of the design surface. The controller automatically maintains or switches control of the milling depth to use the preferred sensor sub-set.