Wireless Sensor System for Construction Equipment Material Flow Control
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Solution Overview
Problem
Cables used in sonic auger and feeder systems for road construction equipment are prone to damage due to proximity to traffic and construction activity, necessitating a solution for cable elimination and improved safety and efficiency.
Innovation Solution
A wireless sensor system with transceivers for over-the-air communication between sensors and a master controller, utilizing 802.15.4 wireless radio links to enable bi-directional data transfer and control of material flow, eliminating the need for physical cables and enhancing bandwidth through dual transceivers for channel scanning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cables are used for sensor connections in construction equipment, then the sensor system can be implemented, but the cables are prone to damage due to proximity to traffic and construction activity
Solution Approach 1:
The patent extracts and removes the cables from the sensor system, replacing them with wireless transceivers. This eliminates the harmful exposure of cables to traffic and construction activity while maintaining the core sensing and communication functions through wireless data transmission between sensors and the control system
Solution Approach 2:
The patent replaces the mechanical cable-based connection system with an electromagnetic wireless communication system. Transceivers transmit sensor data through radio waves instead of physical cable connections, eliminating the mechanical vulnerability of cables to damage from external factors
2Reliability
If cables are used for sensor connections, then the system can be implemented, but additional safety risks are introduced due to cable exposure in busy construction sites
Solution Approach 1:
The cables and their associated safety hazards are extracted from the system. Wireless transceivers are installed on the conveyor and auger, eliminating exposed cable connections that could create tripping hazards, entanglement risks, or electrical safety issues for workers in busy construction environments
Solution Approach 2:
Wireless electromagnetic signals serve as an intermediary medium to transmit sensor data between the conveyor/auger and control system without requiring physical cable connections. This intermediary communication method eliminates the safety risks associated with exposed cables while maintaining system functionality
3Object-affected harmful factors
If wireless transceivers are used for sensor communication, then cable damage is eliminated, but the system complexity increases with dual transceivers for channel scanning
Solution Approach 1:
The transceiver units are designed with multi-functionality, combining sensing, wireless transmission, and intelligent channel management capabilities. The dual transceiver configuration enables both primary communication and proactive channel scanning for interference detection, allowing a single system architecture to handle multiple communication scenarios and improve overall system robustness
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 wireless sensor system effectively controls material flow and reduces cable-related damage risks, improving safety and efficiency by enabling real-time data transmission and proactive channel switching, thus automating construction equipment operations.
Implementation Method 1
A first transceiver in the receiver is in over-the-air communication with the transceiver of the first feeder sensor
Implementation Method 2
sonic auger and sonic feeders are placed in close proximity to people and other moving construction vehicles
Data Source
AI summary
A sensor system for road construction equipment. The system includes a first conveyor for transporting material to a first auger that is positioned to receive the material. A first feeder sensor associated with the first conveyor is in over-the-air communication with a receiver to communicate the height of a material on the conveyor such that a master controller that is electrically connected to the receiver can regulate the amount of flow of material to the first conveyor.