Industrial Vehicle Speed Control Using Calculated Load Estimation
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Solution Overview
Problem
Industrial vehicles face challenges in controlling maximum speed effectively under varying operating conditions, such as load weight, elevation, direction, and surface grade, without direct measurement of the load, which can lead to unsafe braking and inefficient operation.
Innovation Solution
A method and system that determine the torque applied to the traction wheel and acceleration of the industrial vehicle to calculate the load being moved, allowing for control of maximum speed based on the calculated load, taking into account factors like rolling resistance and surface grade, using a processor to estimate the load through averaging individual values and adjusting for operating conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the maximum vehicle speed is controlled based on direct load measurement, then the braking safety is improved, but the device complexity increases due to additional sensors and measurement systems
Solution Approach 1:
The system uses the vehicle's own existing operational parameters (torque, acceleration) to calculate the load being moved, rather than requiring external measurement devices. The processor leverages data already being collected for other vehicle functions to determine load conditions and adjust speed limits accordingly.
Solution Approach 2:
The patent replaces direct mechanical load measurement systems with a computational approach. Instead of using load cells or force sensors to directly measure the load, the system substitutes a mathematical model that calculates load from torque and acceleration data, eliminating the need for complex mechanical measurement infrastructure.
2Measurement precision
If the load is calculated using multiple operating parameters, then the measurement precision is improved, but the device complexity increases due to additional sensors and processing requirements
Solution Approach 1:
The processor uses existing sensors and data collection systems that serve multiple functions. The same torque and acceleration data used for basic vehicle control and monitoring are also utilized for load calculation, making the system multi-functional without requiring additional dedicated hardware for each measurement.
Solution Approach 2:
The system changes the state of data processing by transforming raw sensor data into meaningful load information through mathematical relationships. By changing parameters from individual measurements to calculated composite values, the system achieves precise load estimation using existing hardware capabilities.
3Productivity
If the maximum speed is controlled based on calculated load, then the productivity is improved through efficient operation, but the loss of information increases due to estimation errors without direct measurement
Solution Approach 1:
The system implements a feedback mechanism where the calculated load information is continuously used to adjust the maximum speed limit, which in turn affects vehicle operation and generates new torque and acceleration data. This closed-loop approach allows the system to refine its load estimation over time and adapt to actual operating conditions, reducing information loss through iterative validation.
Data Source
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AI summary
Controlling a maximum vehicle speed for an industrial vehicle (10) includes determining, by a processor (216) of the industrial vehicle, a torque applied to the traction wheel (20) of the industrial vehicle; converting the torque to an equivalent force value; and determining an acceleration of the industrial vehicle while the torque is applied to the traction wheel. Additional steps include calculating a load being moved by the industrial vehicle, based at least in part on the acceleration and the equivalent force value; and controlling the maximum speed of the industrial vehicle based on the calculated load being moved by the industrial vehicle.