Mining Truck Brake Control System for Runaway Prevention
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Solution Overview
Problem
Large mining trucks often remain stationary during operations, leading to potential 'runaway' situations due to forgotten brakes, and existing systems face challenges in accurately detecting stationary periods to prevent false brake activations.
Innovation Solution
A control system that monitors operator inputs and machine speed to determine inactive states, triggering alerts for brake application through audio and visual alarms, and automatically engaging the parking brake if the operator fails to respond after a predetermined time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the control system automatically engages brakes upon detection of stationary period, then runaway truck prevention is improved, but false detection of stationary periods increases
Solution Approach 1:
The control system dynamically adjusts the threshold for detecting stationary periods based on machine speed. When the machine is moving above a predetermined speed threshold, the system does not trigger stationary detection, thereby avoiding false positives during motion while maintaining sensitivity when actually stationary. This dynamic adjustment resolves the contradiction between reliable runaway prevention and accurate stationary detection.
Solution Approach 2:
The system changes the detection parameters (speed threshold) based on the operational state of the machine. By incorporating speed as a variable parameter in the stationary detection logic, the system adapts its sensitivity to match actual operating conditions, preventing false stationary period detection during movement while ensuring reliable detection when the machine is truly stationary.
2Measurement precision
If the control system monitors operator inputs and machine speed continuously, then brake application accuracy is improved, but system complexity increases
Solution Approach 1:
The control system performs multiple functions using a single integrated monitoring mechanism. The same controller that monitors operator inputs also monitors machine speed and determines inactive states, eliminating the need for separate dedicated sensors and control logic for each function. This multi-functionality approach improves detection accuracy while minimizing the increase in system complexity.
Solution Approach 2:
The system merges the monitoring of operator inputs and machine speed into a unified control logic that determines inactive states. By combining these monitoring functions into a single integrated system rather than separate independent systems, the patent achieves accurate inactive state determination without proportionally increasing overall system complexity.
3Loss of time
If the system alerts operator immediately upon stationary detection, then safety response time is improved, but false alerts increase
Solution Approach 1:
The control system performs preliminary speed verification before triggering the stationary detection alert. By checking whether the machine speed is above the predetermined threshold before activating the stationary period detection, the system prevents false alerts from being generated during motion, thereby reducing false alarms while maintaining timely safety warnings when actually stationary.
Data Source
AI summary
A control system for a machine having a brake is disclosed. The control system may include an operator interface configured to receive inputs from an operator of the machine, and output data to the operator of the machine, and a controller in communication with the operator interface. The controller may be configured to monitor operator inputs received by the operator interface, monitor a speed of the machine, and send a signal to the operator interface to notify the operator to apply the brake based at least in part on the operator inputs and the speed of the machine.