Road Cutting Controller Speed-Adaptive Gain
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing road cutting machines for creating rumble strips face challenges in achieving high production rates due to manual control of hydraulic cylinders and require frequent reprogramming of electronic controllers as speed changes, leading to disruptions and inefficiencies.
Innovation Solution
A system and method that utilize a controller programmed to vary proportional gain and depth increments based on six predetermined cutting machine speed input values, with linear interpolation between speed values, allowing continuous adjustment of the cutting drum's movement in response to changing speeds, enabling automatic control of the dimensional profile of rumble strips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual control of hydraulic cylinder is used to raise and lower cutting drum, then ease of operation is maintained, but productivity is insufficient due to operator's inability to move controls quickly enough
Solution Approach 1:
The patent replaces manual mechanical control of the hydraulic cylinder with an electronic controller that automatically controls the hydraulic cylinder based on distance traveled signals. This substitution eliminates the operator's physical limitation in moving controls quickly, thereby increasing productivity while maintaining ease of operation through automated control.
Solution Approach 2:
The system enables self-service by having the electronic controller automatically adjust the cutting drum position based on distance traveled without requiring continuous manual intervention. The controller autonomously manages the hydraulic cylinder operation, allowing the machine to self-regulate its cutting cycle at higher speeds.
2Productivity
If electronic controller is used to achieve better production rates, then productivity is improved, but device complexity increases due to re-programming requirements
Solution Approach 1:
The patent applies preliminary action by pre-programming the electronic controller with instruction parameters for different forward speeds before operation. The controller stores multiple sets of parameters corresponding to different speed ranges, allowing the operator to simply select the appropriate speed range without requiring complex re-programming during operation. This reduces device complexity while maintaining high productivity.
3Productivity
If re-programming of instruction parameters is performed to control cutting drum at increased forward speed, then productivity is improved, but loss of time occurs due to machine stoppage for parameter changes
Solution Approach 1:
The patent implements dynamics by making the electronic controller adaptable to different forward speeds without requiring machine stoppage. The controller is designed to accept and switch between pre-programmed parameter sets corresponding to different speed ranges while the machine is in operation. This dynamic parameter adjustment eliminates time loss due to stoppage while maintaining optimal cutting performance at various speeds.
4Ease of operation
If manual adjustment of depth and hover parameters is made to maintain dimensional profile, then ease of operation is maintained, but manufacturing precision deteriorates due to inability to maintain profile at higher speeds
Solution Approach 1:
The patent applies feedback by using the electronic controller to automatically adjust depth and hover parameters based on signals indicative of distance traveled and forward speed. The controller continuously monitors the cutting process and makes real-time parameter adjustments to maintain the specified dimensional profile, eliminating the inability to maintain precision at higher speeds while reducing manual adjustment requirements.
Data Source
AI summary
A system for controlling a cutting machine for cutting rumble strips in a road surface includes a rotatable cutting head, a cylinder for driving the cutting head out of and into contact with the road surface, and a controller. The controller is programmed to execute an input/output function for varying a proportional gain and an error amplification signal over a range of forward speed of the cutting machine. An I/O function is based on six predetermined cutting machine speed values; wherein a proportional gain and a depth increment are specified for each speed value. The respective speed values increase progressively. As an actual forward speed of the cutting machine varies between two of the six predetermined input speed values a linear interpolation is applied between the next lower and the next greater speed value to vary the instantaneous proportional gain and depth increment to be applied by the controller.