Concrete Mixer Lift Axle Control for Fill-Based Weight Distribution
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Solution Overview
Problem
Conventional vehicle control systems for vehicles like concrete mixers require manual operation to engage and disengage lift axles, which is inefficient and can lead to uneven weight distribution, causing wear on roads and reducing fuel efficiency.
Innovation Solution
A control system that includes a controller connected to a fill level sensor, GPS, and tire pressure sensor to automatically adjust the position of lift axles based on the fill level of the mixing drum, ensuring optimal weight distribution and reducing manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual operation is used to engage and disengage lift axles, then the system is simple to operate, but fuel efficiency decreases and road wear increases due to uneven weight distribution
Solution Approach 1:
The system automatically monitors drum fill level via sensors and autonomously adjusts lift axle positions without requiring manual intervention. The controller receives fill level signals and actuates the lift axle mechanism accordingly, enabling the system to self-regulate weight distribution based on actual load conditions
Solution Approach 2:
The system incorporates fill level sensors that continuously monitor the mixing drum's load and provide feedback signals to the controller. This feedback loop enables real-time detection of weight changes and automatic adjustment of axle positions to maintain optimal weight distribution, directly improving fuel efficiency and reducing road wear
2Device complexity
If manual operation is used to control lift axles, then the control system is simple, but productivity decreases due to inefficiency and lack of dynamic adjustment
Solution Approach 1:
The control system autonomously manages lift axle positioning by monitoring fill level sensors and automatically actuating the appropriate axles. This eliminates the need for manual operation while significantly improving operational efficiency through dynamic, real-time adjustments that optimize weight distribution throughout the vehicle's operation
Solution Approach 2:
The patent replaces manual mechanical control with an automated electronic control system that uses sensors, controllers, and electronic actuators. This substitution of manual operation with automated electronic control enhances productivity while managing system complexity through integrated electronic components
3Object-affected harmful factors
If additional axles are added to distribute gross weight, then road wear is reduced when loaded, but the vehicle complexity increases and fuel efficiency decreases when unloaded
Solution Approach 1:
The lift axles are designed to be dynamically repositionable between engaged and disengaged states based on real-time load conditions. When the drum is filled, the system automatically engages additional axles to distribute weight and reduce road wear; when unloaded, the axles are automatically raised to reduce vehicle complexity and improve fuel efficiency
Solution Approach 2:
The lift axle mechanism serves multiple functions: it provides additional weight distribution capability when needed to reduce road wear, and can be retracted when not needed to maintain fuel efficiency. This multi-functional design allows the same structural components to serve different operational requirements
4Object-affected harmful factors
If lift axles are continuously engaged to distribute weight, then road wear is minimized, but fuel efficiency decreases due to increased rolling resistance
Solution Approach 1:
The system dynamically adjusts lift axle engagement based on real-time drum fill level monitoring. Additional axles are engaged only when the drum is filled and weight distribution is needed to reduce road wear, and automatically disengaged when the drum is empty to minimize rolling resistance and fuel consumption
Solution Approach 2:
The system changes the operational parameters of the lift axles (engaged/disengaged state) based on drum fill level conditions. This parameter adjustment ensures that additional axles are activated only when necessary for weight distribution, optimizing the balance between reducing road wear and minimizing fuel consumption
Data Source
AI summary
A concrete mixing truck includes a chassis, a front axle and a rear axle coupled to the chassis, a lift axle coupled to the chassis and including a tractive element, a lift actuator coupled to the lift axle, a mixing drum rotatably coupled to the chassis, a fill level sensor coupled to the mixing drum and configured to provide a signal indicative of a fill level of a material within the mixing drum, and a controller. The lift axle is selectively repositionable between a lowered position in which the tractive element engages a support surface and a raised position. The controller is operatively coupled to the lift actuator and the fill level sensor and configured to control the lift actuator to reposition the lift axle into the lowered position in response to the fill level exceeding a threshold fill level.