Material Transfer Vehicle Sensor Automation

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Solution Overview

Problem

The existing road paving process is inefficient due to manual coordination of material delivery, leading to inconsistencies in asphalt supply and quality, which results in uneven road surfaces and increased labor and time costs.

Innovation Solution

A system that automates the dump routine of the loading hopper in a material transfer vehicle (MTV) using sensors and controllers to initiate, execute, and terminate the unloading process based on specific conditions, eliminating the need for a dedicated dump operator and optimizing material delivery timing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual coordination of material delivery is used, then labor flexibility is maintained, but paving efficiency and consistency deteriorate

Engineering Contradiction:

Improvepaving efficiencyVSAvoidmanual coordination complexity

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The MTV is equipped with sensors that automatically detect material levels in the hopper and trigger unloading operations without manual intervention. The system monitors its own material supply status and initiates the unloading sequence autonomously when material levels drop below a threshold, eliminating the need for manual coordination while maintaining continuous paving operations.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual coordination of material delivery is replaced by an automated control system that uses sensors to detect material levels and electronically controls the unloading mechanism. The mechanical action of manual monitoring and coordination is substituted with electronic sensing and automated actuation systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Stability of the object's composition

If continuous unloading operation is maintained, then material supply consistency improves, but energy consumption increases

Engineering Contradiction:

Improvematerial supply consistencyVSAvoidfeeder energy consumption

Core Design Contradiction:

Stability of the object's compositionVSUse of energy by moving object

Solution Approach 1:

Instead of continuous operation, the feeder operates periodically based on material level detection. The unloading mechanism is activated only when sensors detect that material levels have dropped below a threshold, creating an on-demand periodic operation pattern that maintains material supply consistency while minimizing unnecessary energy consumption during adequate material supply periods.

Inventive Principle:

Principle #19Periodic action

3Extent of automation

If automated sensor system is implemented, then labor requirements are reduced, but device complexity increases

Engineering Contradiction:

Improvedump routine automationVSAvoidsensor and controller system complexity

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The sensor system and controller are integrated into the existing MTV control architecture, allowing the same control unit to perform both traditional operational functions and the new automated material level monitoring and unloading trigger functions. This multi-functionality approach reduces overall system complexity by reusing existing components rather than adding entirely separate automated subsystems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11731840B2Truck detection sensor for material transfer vehicles

Publication Date: 2023.08.22 WEILER & CO INC

AI summary

Disclosed is an example material transfer vehicle comprising a feeder having a hydraulic motor, a chain actuated by the hydraulic motor, and loading hopper configured to provide material to the chain; a sensor configured to detect a presence of a truck; and an electronic control module, wherein the electronic control module is configured to automatically increase a speed at which the chain is actuated when the sensor detects a presence of a truck.