Concrete Mixer Drum Load Detection via Cradle Strain
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Solution Overview
Problem
Existing methods for determining the amount of concrete in a mixer drum are neither accurate nor convenient, as they rely on direct weighing, which is imprecise due to factors like fuel tank fluctuations, and do not provide real-time measurements, limiting the ability to monitor drum buildup and maintenance needs.
Innovation Solution
A load measurement system that indirectly calculates the concrete amount by measuring strain and displacement of a cradle receiving the mixing drum, using sensors such as strain gauges, potentiometers, and accelerometers to determine material deformation, displacement, and vibration, allowing for remote monitoring and alerting of symmetric and asymmetric buildup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If direct weighing methods are used to determine concrete load, then measurement can be obtained, but accuracy deteriorates due to scale imprecision and fuel tank fluctuations
Solution Approach 1:
The patent introduces an intermediary measurement approach by measuring cradle displacement and material property changes rather than directly weighing the concrete. This intermediary measurement method avoids the problems of direct weighing (scale imprecision, fuel tank fluctuations) while still providing accurate concrete load determination through indirect measurement of the cradle's response to the drum's weight.
Solution Approach 2:
The patent replaces the mechanical weighing system with a sensor-based measurement system that detects material property changes (displacement, strain) in the cradle. This substitution transitions from direct mechanical weight measurement to indirect physical property measurement, eliminating the harmful factors associated with traditional weighing methods.
2Measurement precision
If traditional weighing systems are used, then load measurement is possible, but real-time monitoring capability is lost
Solution Approach 1:
The patent implements continuous monitoring by placing sensors on the cradle that continuously measure displacement and material property changes. This allows real-time tracking of concrete quantity throughout the mixing and delivery process, enabling continuous useful action rather than intermittent or post-process measurement.
Solution Approach 2:
The system provides feedback by continuously measuring cradle properties and translating them into concrete quantity information. This feedback mechanism enables real-time monitoring and allows operators to know the current load status at any point during operation, not just after delivery.
3Measurement precision
If weight scales are used for measurement, then concrete load can be determined, but device complexity and operational inconvenience increase
Solution Approach 1:
The cradle serves itself as the measurement platform - the same structural component that supports the drum also serves as the sensor mounting platform. This self-service approach eliminates the need for separate weighing infrastructure, making the system easier to operate and integrate into existing mixer equipment.
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
Enables accurate, real-time monitoring of concrete quantity and drum conditions, improving concrete quality and equipment maintenance by providing continuous load measurements and predictive alerts for potential failures.
Implementation Method 1
measurements pertaining to the strain and/or displacement, of a cradle receiving a drum of the concrete mixer
Implementation Method 2
measurements pertaining to the strain and/or displacement, of a cradle receiving a drum of the concrete mixer
Data Source
AI summary
A load measurement system for a mixer comprising a mixing drum configured to contain and mix concrete, a cradle adjacent to the mixing drum and configured to receive the mixing drum, and a load measurement device adjacent to the cradle and configured to determine the changes to a material property of the cradle due to the force exerted on the cradle by the load in the mixing drum. The load measurement system determines the amount of the load of concrete in the mixing drum based on the measured change to the material property of the cradle, which may include one or more of a material deformation, displacement, stress, strain, or the vibration of the cradle.