Modular Measuring System for Construction Machine Screed Control
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Solution Overview
Problem
Existing road construction machinery systems require significant installation effort for distance sensors, such as the Big Sonic Ski, which compromises between installation effort, measuring range, and reliability, and suffer from disturbances that affect screed height leveling accuracy.
Innovation Solution
A modular measuring system with a carrier comprising multiple sensor heads connected via mechanical and electrical elements, allowing for simultaneous measurement at multiple points, and a dual control loop system for screed height adjustment to compensate for different disturbances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple individual sensor heads are installed separately to achieve multi-point measurement, then measurement reliability is improved, but installation effort and assembly time increase significantly
Solution Approach 1:
Multiple sensor heads are integrated into a single modular carrier unit that can be installed as one component. The carrier contains mounting structures for multiple sensors (e.g., 3-5 sensors) along with shared electronics and power supply, transforming what would be multiple separate installations into a single assembly operation.
Solution Approach 2:
The measuring system is divided into modular carriers that can be independently installed and configured. Each carrier is a self-contained module with its own sensor array and electronics, allowing for standardized installation procedures and reducing the complexity of wiring and mounting individual sensors separately.
2Measurement precision
If individual sensor heads are installed separately with individual wiring, then measurement precision is improved, but device complexity increases
Solution Approach 1:
Multiple sensor heads share common electronics, power supply, and signal processing circuits within the carrier. This consolidation maintains the individual measurement capabilities of each sensor while eliminating the need for separate wiring harnesses and control circuits for each sensor, thereby reducing device complexity.
Solution Approach 2:
The carrier serves multiple functions simultaneously: it provides mechanical mounting for multiple sensors, houses shared electronics and power supply, and implements signal processing for all sensors. This multi-functionality reduces the overall system complexity while maintaining measurement precision.
3Device complexity
If a single control loop is used for screed height adjustment, then device complexity is reduced, but measurement precision deteriorates due to unaddressed disturbances
Solution Approach 1:
The control system is divided into separate control loops that independently address different disturbance sources. One control loop compensates for chassis-level disturbances (e.g., terrain variations, machine vibrations) while another loop addresses screed-specific disturbances (e.g., material flow variations, screed flexibility). This segmentation improves precision while keeping each individual control loop relatively simple.
Solution Approach 2:
The patent introduces intermediate measurement points and sensors that detect disturbances at different levels of the system hierarchy. These intermediate measurements allow the control system to identify and compensate for specific disturbance sources before they affect the final screed height, improving precision without requiring an overly complex monolithic control system.
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
Reduces assembly time and enhances measurement reliability by minimizing individual sensor head installation, and improves screed height leveling by individually addressing chassis and screed disturbances.
Implementation Method 1
ultrasonic sensors have become established on the market for this purpose
Implementation Method 2
The three ultrasonic sensors 5a, 5b, 5c serve to scan a reference surface
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
The invention relates to a measuring system for a construction machine with a carrier having several sections, a measuring system for a construction machine with a calculation unit that determines a regression line, and a control system with two control loops.