Refuse Vehicle Load Limiting Mechanism Prevents Overloading

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Solution Overview

Problem

Modern refuse vehicles, designed to be lighter and more fuel-efficient, face challenges in accurately estimating payload weight due to variable refuse densities and conditions, leading to potential overloading and risk of vehicle damage, as they lack a reliable weight-based load limiting mechanism.

Innovation Solution

A refuse vehicle equipped with a hopper, lift mechanism, gripper, weight sensor, and controller that inhibits operation if the weight exceeds a predetermined value, ensuring the payload does not exceed the vehicle's capacity, thereby preventing overloading.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If refuse vehicles are designed to be lighter and more fuel-efficient, then fuel efficiency is improved, but payload capacity is reduced

Engineering Contradiction:

Improvefuel efficiencyVSAvoidpayload capacity

Core Design Contradiction:

Use of energy by moving objectVSQuantity of substance

Solution Approach 1:

The patent implements a weight sensing system that continuously monitors the payload weight and provides feedback to the control system. When the predetermined weight limit is approached or exceeded, the system automatically activates the alarm and prevents further loading operations, creating a closed-loop feedback mechanism that ensures optimal payload utilization without overloading.

Inventive Principle:

Principle #23Feedback

2Productivity

If operators maximize payload capacity, then productivity is improved, but risk of vehicle damage increases

Engineering Contradiction:

Improvepayload maximizationVSAvoidvehicle safety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system takes preliminary anti-action by establishing a predetermined weight limit before overloading occurs. The weight sensing system continuously monitors the payload and triggers the alarm and lockout mechanisms before the vehicle is damaged, preventing the harmful effect of overloading rather than merely detecting it after the fact.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The control system acts as an intermediary between the loading operations and the vehicle structure. It receives weight information from the sensing system, processes it against the predetermined limit, and intermediates by preventing further loading through the alarm and lockout mechanisms when the limit is approached, thereby protecting the vehicle from overload damage.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If operators return to processing center before container is full, then vehicle safety is maintained, but productivity decreases

Engineering Contradiction:

Improvevehicle safetyVSAvoidcollection efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system provides continuous feedback on the vehicle's loading status through the weight sensing and alarm system. Operators receive real-time information about how close the vehicle is to its weight limit, enabling them to maximize collections without overloading and plan returns to the processing center more efficiently based on actual payload status rather than conservative estimates.

Inventive Principle:

Principle #23Feedback

4Device complexity

If no weight monitoring system is installed, then device complexity is reduced, but measurement precision of payload weight is insufficient

Engineering Contradiction:

Improvesystem simplicityVSAvoidpayload weight estimation

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent replaces manual weight estimation methods with an automated electronic weight sensing system. The sensor-based weight detection and electronic control system automatically measures and monitors payload weight, eliminating the need for manual estimation and providing precise weight data to the operators.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical 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

The load limiting system effectively prevents overloading by sensing and controlling the weight of refuse, ensuring safe operation and maximizing payload without damaging the vehicle, while allowing operators to manage collections efficiently.

Implementation Method 1

A sensor senses a weight that varies in accordance with the refuse contained in the hopper

Methodology Applied

Scientific EffectWeight sensing: Gravitation

Data Source

PatentUS9902559B2Scale based load limiting mechanism for refuse vehicles with an intermediate container

Publication Date: 2018.02.27 HEIL CO

AI summary

A weight based load limiting system for a refuse vehicle. The system includes a weight determination module that generates a signal that varies in accordance with a vehicle weight. If the vehicle weight approaches or exceeds a predetermined maximum weight, the signal inhibits a portion of the loading or packing operation to prevent overloading the vehicle. In various configurations, the system prevents a lifting of a refuse container to prevent emptying of the container into the vehicle hopper. In other various configurations, the system prevents gripping of a refuse can.