Mixer Drum Load Sensing for Concrete Buildup Position Detection
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Solution Overview
Problem
Concrete mixer vehicles face inefficiencies due to concrete buildup within the mixer drum, leading to uneven weight distribution, reduced delivery capacity, and potential maneuverability issues, as existing methods rely on manual inspection or expensive load cells for detection.
Innovation Solution
A concrete buildup location determination system is integrated into the vehicle, featuring a load sensor and control system that monitor the force applied by the drum to the chassis, determining the longitudinal position of the buildup and generating notifications or control signals to address the issue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection methods are used to detect concrete buildup, then the system complexity is low, but the detection precision and reliability are insufficient
Solution Approach 1:
The patent replaces manual inspection methods with an automated load detection system that uses load sensors to measure force applied by the drum to the chassis. This mechanical-to-electronic substitution enables precise, objective detection of concrete buildup without requiring human intervention, directly resolving the contradiction between detection precision and system complexity.
Solution Approach 2:
The patent introduces a control system as an intermediary between the load sensor and the user. The control system processes sensor data, determines longitudinal position of concrete buildup, and generates notifications or control signals. This intermediary layer translates raw mechanical measurements into actionable information, maintaining simplicity while achieving high detection precision.
2Measurement precision
If expensive load cells are used for detection, then the measurement precision improves, but the manufacturing cost increases
Solution Approach 1:
The patent employs load sensors positioned at strategic locations (proximate to forward end or rear end of drum) that provide sufficient measurement precision at lower cost compared to traditional load cells. The system uses these sensors to detect changes in force that indicate concrete buildup, achieving accurate detection without the high manufacturing cost of expensive load cells.
Solution Approach 2:
The patent segments the detection function by positioning load sensors at specific locations along the drum-chassis interface rather than using a single comprehensive load cell. This segmentation allows the system to detect longitudinal position of concrete buildup by measuring force distribution at multiple points, achieving both precision and cost-effectiveness through distributed sensing.
3Productivity
If concrete buildup is not detected, then the vehicle operates continuously without interruption, but the weight distribution becomes uneven and delivery capacity is reduced
Solution Approach 1:
The patent implements a feedback mechanism where the load sensor continuously monitors force applied by the drum, the control system processes this data to detect concrete buildup and determine its longitudinal position, and the system generates notifications or control signals. This closed-loop feedback enables real-time detection and response to concrete buildup, maintaining reliable vehicle performance and optimal delivery capacity by preventing uneven weight distribution.
Solution Approach 2:
The patent enables preliminary detection of concrete buildup before it significantly impacts vehicle performance. By continuously monitoring load variations and determining the longitudinal position of buildup, the system can alert operators or automatically adjust operations before uneven weight distribution deteriorates delivery capacity, maintaining both productivity and reliability.
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
Automatically detects concrete buildup and its position, enabling timely cleaning and redistribution of weight, thus improving vehicle performance and efficiency by preventing uneven loading and extending delivery capacity.
Implementation Method 1
The load sensor is configured to determine a portion of a force applied by the drum to the chassis
Data Source
AI summary
A vehicle includes a chassis, a drum, a load detection system, and a control system. The drum is coupled to the chassis and is configured to mix drum contents received therein. The load detection system is coupled to the chassis and includes a load sensor. The load sensor is positioned proximate to one of a forward end of the drum and a rear end of the drum. The load sensor is configured to determine a portion of a force applied by the drum to the chassis. The control system is communicably coupled to the load detection system and is configured to determine a longitudinal position of a concrete buildup in the drum based on the portion. The control system is also configured to generate at least one of a notification indicating the longitudinal position or a control signal based on the longitudinal position.