Payload Weight Calculation via Strut Force Adjustment
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Solution Overview
Problem
Current payload weight calculation methods for off-highway machines, such as dump trucks, face challenges in achieving high accuracy, with existing systems providing payload weight measurements with an accuracy of around plus or minus 5%, which is not sufficient for improved efficiency and profitability evaluations.
Innovation Solution
A method and system that calculates payload material weight by determining the forces on front and rear struts in both loaded and unloaded conditions, adjusting for friction forces, and using an electronic controller to calculate the weight difference between loaded and unloaded states, incorporating tunable parameters like strut friction coefficients and areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional strut pressure measurement methods are used, then the system is simple to implement, but the payload weight accuracy is limited to around plus or minus 5%
Solution Approach 1:
The patent applies parameter changes by introducing multiple tunable parameters (friction coefficients for front and rear struts, area moments of inertia for front and rear struts, and dump body weight) that can be adjusted to optimize measurement accuracy. The electronic controller uses these parameters in conjunction with strut pressure measurements to calculate payload weight with accuracy exceeding 5%, resolving the contradiction between measurement precision and device complexity by making the system adaptable through parameter tuning rather than requiring complex hardware modifications.
2Measurement precision
If friction forces are not adjusted for in calculations, then the calculation process is simpler, but the payload weight measurement accuracy deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-determining friction coefficients and area moments of inertia for the struts before actual payload measurements are taken. These parameters are established in advance and stored in the electronic controller, allowing the system to automatically compensate for friction effects during normal operation without requiring complex real-time calculations or manual adjustments, thus maintaining both accuracy and operational simplicity.
3Measurement precision
If only basic strut pressure measurements are used, then the system is easier to operate, but it cannot provide the improved accuracy needed for efficiency and profitability evaluations
Solution Approach 1:
The patent applies feedback by using the electronic controller to continuously monitor strut pressures and automatically adjust calculations based on the relationship between loaded and unloaded weight measurements. The system incorporates feedback loops that use predetermined parameters and real-time pressure data to refine payload weight calculations, ensuring accuracy exceeds 5% while maintaining automated operation that simplifies user interaction despite the sophisticated underlying calculations.
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
This approach enhances payload weight calculation accuracy beyond existing methods, enabling more precise evaluations of payload material weight, improving operational efficiency and profitability assessments.
Implementation Method 1
measuring suspension strut pressures of the truck and using a combination of formulas and empirical data to calculate the payload weight
Implementation Method 2
adjusting the forces for friction forces
Data Source
AI summary
A method of calculating payload material weight is executable by an electronic controller of a machine and includes steps of determining a first force on first front and rear struts of the machine in an unloaded condition of the machine, and adjusting the first force based on at least one of an unloaded front strut friction force and an unloaded rear strut friction force to define an unloaded weight. The method also includes steps of determining a second force on the first front and rear struts in a loaded condition of the machine, and adjusting the second force based on at least one of a loaded front strut friction force and a loaded rear strut friction force to define a loaded weight. A payload material weight is calculated by the method based on a difference between the loaded weight and the unloaded weight.