Tipper Vehicle Control System with Sensor-Based Safety Interlocks

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Solution Overview

Problem

Current tipper vehicle control systems lack the ability for operators to monitor the operating conditions of actuators and detect potential hazards, such as failed pin engagement, fully lowered body positions, and underrun protection bar operation, leading to safety risks and inefficiencies.

Innovation Solution

A multifunctional control system with sensors and a central control unit connected to a touch-operated graphical interface, which includes sensors for detecting wall, pin, cylinder, brake, and underrun protection bar positions, and acoustic or visual alerts to warn operators of anomalies, ensuring safe and controlled tipping operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of information

If a basic control system is used for tipper vehicle operation, then the device complexity is low, but the operator cannot monitor operating conditions or detect potential hazards

Engineering Contradiction:
Improveoperator awareness of system stateVSAvoidcontrol system complexity
Core Design Contradiction:
Loss of informationVSDevice complexity

Solution Approach 1:

The patent implements multiple sensors that continuously monitor the operating state of the tipper body (position, tipping angle, load weight) and provide real-time feedback to the control system. This feedback mechanism enables the operator to see the current state of the system through the graphical interface, resolving the information loss problem while maintaining manageable complexity through automated sensing.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The patent introduces a graphical interface as an intermediary between the complex sensor network/control system and the operator. This interface translates raw sensor data into intuitive visual representations, allowing the operator to monitor system state without being overwhelmed by technical complexity. The intermediary layer bridges the gap between sophisticated monitoring capabilities and simple operator interaction.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Reliability

If manual operation procedures are used, then the ease of operation is high, but safety hazards occur due to undetected pin engagement failures or wrong-side tipping

Engineering Contradiction:
Improvesafety of tipping operationVSAvoidoperational simplicity
Core Design Contradiction:
ReliabilityVSEase of operation

Solution Approach 1:

The control system performs preliminary checks before allowing tipping operations to proceed. It verifies pin engagement status, body position, and other safety conditions through sensors, and only permits operation when conditions are safe. This preliminary verification prevents hazardous operations while maintaining ease of use through automated safety checks.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors critical parameters such as pin engagement status and body position, providing real-time feedback to prevent unsafe operations. If a hazard is detected (e.g., incomplete pin engagement), the system automatically prevents tipping or alerts the operator, ensuring safety without requiring complex manual procedures.

Inventive Principle:
Principle #23Feedback

3Reliability

If comprehensive monitoring of all actuators and components is implemented, then the reliability of safe operation is improved, but the device complexity increases

Engineering Contradiction:
Improvemonitoring accuracyVSAvoidnumber of sensors and control elements
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent employs a multi-functional control system where a single integrated controller handles multiple tasks: monitoring pin engagement, tracking body position, measuring load weight, controlling the graphical interface, and managing safety interlocks. This universal approach consolidates multiple monitoring functions into one system, improving reliability through comprehensive coverage while controlling complexity through integration.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines multiple sensing functions (position sensors, weight sensors, pin engagement detectors) and control functions into a unified control system. By merging these separate functions into an integrated architecture, the system achieves comprehensive monitoring capability while avoiding the complexity of multiple independent control systems. The graphical interface also merges multiple information displays into a single coherent view.

Inventive Principle:
Principle #5Merging (Combining)

Data Source

PatentEP3833570B1Multifunctional control system for use in a tipper vehicle
Publication Date: 2022.02.02 ITALAUTO CAR
  • EP3833570B1 patent drawingFigure 1~3
  • EP3833570B1 patent drawingFigure 4~5
  • EP3833570B1 patent drawingFigure 6

AI summary

A multifunctional control system in combination with a vehicle (1 ) having a frame (2), a subframe (3), a tipper body (4) with a plurality of walls (6, 7), which is connected to the subframe (3) via a plurality of spherical supports (5), adapted to be selectively locked by means of pins (14), a lift cylinder (17) for lifting the body (4), a brake (10), a power takeoff (11) and an underrun protection bar (18). The control system comprises a plurality of sensors (23- 29) respectively for detecting the position of the walls (6, 7), the pins (14) and the cylinder (17), the operation of the brake (10), the engagement of the power takeoff (11) and the position of the bar (18), a central control unit (22) with sensors (23-29) connected thereto, and a terminal (30) connected to the unit (22) and designed to be actuated by an operator. The terminal (30) is an electronic device of tablet type having a touch-operated graphical interface (31 ) which is configured to select the tasks of opening the walls (6, 7), tipping the body (4) and positioning the bar (18) only if the power takeoff (11) is engaged, and comprises a speed limiter (32) and/or an acoustic or visual alert device (33) which is configured to be automatically operated to reduce the rotation speed of the engine and/or warn the operator about faults and hazard conditions if the body (4) remains in the lifted state and at least one wall (6, 7) remains in the open position.