Radar Truck Hopper Alignment Through Dust

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Solution Overview

Problem

Aligning the feed hopper of a concrete truck with the discharge chute at a concrete plant is challenging due to dust and environmental dust shields, which hinder the effectiveness of visual alignment methods and result in inefficiencies and material waste.

Innovation Solution

A concrete truck alignment system utilizing an electronic sensor, such as radar, that can see through dust and environmental dust shields to determine the hopper offset and provide feedback for alignment, using graphical or auditory signals to indicate the necessary adjustments for proper alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If visual alignment methods (cameras, video equipment) are used to align the feed hopper with the discharge chute, then alignment can be assisted, but the equipment cannot function properly due to dust and dust shields blocking the visual field

Engineering Contradiction:

Improvealignment assistanceVSAvoiddust and dust shield interference

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent replaces visual alignment methods (optical systems) with radar-based detection. The radar system emits electromagnetic waves that can penetrate dust and dust shields, allowing the feed hopper's position to be detected and displayed on a screen without being blocked by particulate matter or shielding structures.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system changes the detection parameter from optical (visual) to electromagnetic (radar). By using radar waves instead of visible light, the system can operate effectively in dusty environments where optical methods fail, as radar waves are not scattered or absorbed by dust particles in the same way light is.

Inventive Principle:

Principle #35Parameter changes

2Measurement precision

If a dedicated person guides the truck alignment manually, then alignment can be achieved, but productivity is reduced due to the time-consuming nature of manual guidance

Engineering Contradiction:

Improvealignment accuracyVSAvoidloading speed

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The radar system enables the truck driver to self-align the feed hopper with the discharge chute by viewing the position information on the screen. This eliminates the need for a dedicated guide person, allowing the driver to perform the alignment task independently and more efficiently.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system provides real-time feedback by displaying the feed hopper's position relative to the discharge chute on a screen. This immediate visual feedback allows the driver to make precise adjustments to achieve accurate alignment, maintaining high measurement precision while speeding up the process.

Inventive Principle:

Principle #23Feedback

3Loss of information

If the camera is mounted outside the dust shield, then the discharge chute should be visible, but the dust shield blocks the view even if made of clear material

Engineering Contradiction:

Improvevisibility of discharge chuteVSAvoiddust shield obstruction

Core Design Contradiction:

Loss of informationVSObject-affected harmful factors

Solution Approach 1:

The patent substitutes optical detection (cameras) with radar detection. The radar system can detect the feed hopper's position through dust and dust shields without requiring line-of-sight visibility, thereby eliminating the problem of the dust shield blocking the view.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The radar waves act as an intermediary that can penetrate the dust shield and dust environment to detect the feed hopper's position. Instead of relying on direct visual contact between the camera and the discharge chute, the radar waves serve as a mediator that carries position information through the obstructive medium.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 precise alignment of the feed hopper to the discharge chute, reducing material waste and improving operational efficiency by providing accurate positioning feedback through dust-shielded environments.

Implementation Method 1

The sensor may use radar

Methodology Applied

Scientific EffectRadar: Radar

Data Source

PatentUS10800618B1Alignment system and method for a concrete truck at a concrete plant or a cement tanker at a cement loading station

Publication Date: 2020.10.13 FAULKNER GEORGE WAYNE

AI summary

A concrete truck or cement tanker truck alignment system with a loading station having a discharge chute, an electronic sensor that sees through dust or an environmental dust shield, and provides location information used to determine a hopper offset. The hopper offset is a measurement of the physical offset between a feed hopper on the truck and the discharge chute. The system may further include an alignment feedback unit that provides feedback based on the hopper offset. The alignment feedback unit may indicate the hopper offset is within an alignment tolerance. The sensor may use radar. The alignment feedback unit may provide auditory or graphical feedback. The graphical feedback may show a discharge icon representing the position of the discharge chute and a hopper icon representing the feed hopper where the location of the hopper icon is relative to the discharge chute based on the hopper offset.