U.S. patent application number 12/015748 was filed with the patent office on 2008-08-28 for electrohydraulic control system for a vehicle.
This patent application is currently assigned to MUNCIE POWER PRODUCTS, INC.. Invention is credited to Terry Crago.
Application Number | 20080201994 12/015748 |
Document ID | / |
Family ID | 39333668 |
Filed Date | 2008-08-28 |
United States Patent
Application |
20080201994 |
Kind Code |
A1 |
Crago; Terry |
August 28, 2008 |
ELECTROHYDRAULIC CONTROL SYSTEM FOR A VEHICLE
Abstract
An electronic control system and data-logging system for a snow
removal vehicle. The vehicle includes hydraulically actuated tools,
the control of which can be through a dual axis controller such as
a joystick. Electrical communication among components in the system
is provided by a power line carrier protocol (PLC).
Inventors: |
Crago; Terry; (Lapel,
IN) |
Correspondence
Address: |
BINGHAM MCHALE LLP
2700 MARKET TOWER, 10 WEST MARKET STREET
INDIANAPOLIS
IN
46204-4900
US
|
Assignee: |
MUNCIE POWER PRODUCTS, INC.
Muncie
IN
|
Family ID: |
39333668 |
Appl. No.: |
12/015748 |
Filed: |
January 17, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60880901 |
Jan 17, 2007 |
|
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Current U.S.
Class: |
37/197 ;
37/234 |
Current CPC
Class: |
E01H 5/06 20130101 |
Class at
Publication: |
37/197 ;
37/234 |
International
Class: |
E01H 5/00 20060101
E01H005/00 |
Claims
1. An apparatus for controlling a snowplow of a vehicle,
comprising: a hydraulically actuatable snowplow mounted to the
vehicle and movable over a range of positions; a hydraulic actuator
for moving said snowplow over the range at a rate of movement; an
electrohydraulic interface unit which receives an actuation signal
and provides hydraulic fluid to said actuator in response thereto;
an electrical interface unit which receives a command signal and
produces said actuation signal in response thereto; a joystick
movable in a direction over a range of positions and providing a
first data signal which is proportional to the position of said
joystick; and a keypad having first and second manual switches,
said first switch providing a fixed predetermined second data
signal when switched, said second switch providing a fixed
predetermined third data signal when switched; wherein said first
data signal, said second data signal, and said third data signal
correspond to a desired rate of movement of said snowplow, and one
of said first data signal, said second data signal, or said third
data signal correspond to said command signal.
2. The apparatus of claim 1 wherein said keypad produces said
actuation signal in response to one or the other of said joystick
or said keypad
3. The apparatus of claim 1 which further comprises a hydraulically
actuatable dump body mounted to the vehicle and movable over a
second range of positions; a second hydraulic actuator for moving
said dump body over the second range at a rate of movement; said
electrohydraulic interface unit receiving a dump signal and
providing hydraulic fluid to said second actuation in response
thereto; and a selection switch providing a selection signal to
said electrical interface unit, said electrical interface unit
using the state of said selection switch to determine if said first
data signal corresponds to movement of said dump body or movement
of said snowplow.
4. The apparatus of claim 3 wherein if said joystick remains
centered for a more than a predetermined period time, the
electrical interface unit automatically correspond said first
signal to movement of said snowplow.
5. The apparatus of claim 1 wherein said electrohydraulic interface
unit includes at least one proportional solenoid and at least one
spool valve, said solenoid applying a force to said valve which is
proportional to said actuation signal.
6. The apparatus of claim 1 wherein the vehicle includes a DC
electrical system, said actuation signal is at a frequency, and
said electrical interface unit places said actuation signal on said
DC electrical system.
7. The apparatus of claim 1 which further includes a third switch
adjustable by the vehicle operator and providing an output variable
between high and low limits, wherein the output of said third
switch establishes said second data signal.
8. An apparatus for controlling the snow removal functions of a
vehicle, comprising: a vehicle including a hydraulically actuatable
snowplow and a second actuatable tool; an electrohydraulic
interface unit which receives an actuation signal and provides
hydraulic fluid to said snowplow or said tool in response thereto;
an electrical interface unit which receives a command signal and
produces said actuation signal in response thereto, said interface
unit receiving an identification signal and responsive to select
one of said snowplow or said tool for actuation in response
thereto; and a joystick movable in each of two directions over a
range of positions and providing said command signal which is
proportional to the position of said joystick, said joystick
including a first switch and a second switch; wherein the states of
said first switch and second switch provides said identification
signal
9. The apparatus of claim 8 wherein said command signal is
proportional to the rate of movement of said snowplow or said
tool.
10. The apparatus of claim 8 wherein said electrical interface unit
responds to said identification signal only if said joystick is
generally centered.
11. The apparatus of claim 8 which further comprises a
hydraulically actuatable dump body and a third switch, said
electrohydraulic interface unit providing hydraulic fluid to dump
body, said electrical interface unit selecting one of said
snowplow, said tool, or said dump body for actuation, and wherein
the states of said first switch, second switch, and said third
switch provides said identification signal.
12. The apparatus of claim 8 wherein said joystick includes a
deadman switch providing a signal to said electrical interface unit
corresponding to the presence of a user of the vehicle, said
electrical interface unit providing said actuation signal only if
the user is present.
13. The apparatus of claim 8 wherein said joystick includes dual
redundant sensors for providing said command signal.
14. The apparatus of claim 8 wherein said joystick is centerable in
each of the two directions and said electrical interface unit is
programmable to apply a deadband region to each direction.
15. A method for controlling the snowplow of a truck, comprising:
providing a truck having an actuatable snowplow actuatable in each
of two directions at a variable rate of movement and a two axis
controller, wherein the controller is moveable in each axis over a
range of positions, the snowplow is actuatable in each direction
over a range of rates of movement, and the range of positions
corresponds to the range of rates; moving the snowplow in one
direction at a predetermined rate in response to movement of the
controller in one axis to a predetermined position; and moving the
snowplow in the other direction at a predetermined rate in response
to movement of the controller in the other axis to a predetermined
position.
16. The method of claim 15 further comprising providing the truck
with a dump body actuatable in a direction over a range of rates of
dumping movement, and the range of positions is capable of
corresponding to the range of rates of dumping movement; selecting
the range of positions to correspond to the range of rates of
dumping movements and preventing the range of positions from
corresponding to the range of rates of snowplow movement.
17. A system for electronically logging the snow and ice removal
functions of a vehicle, comprising: a vehicle having an electrical
power system and including a snowplow hydraulically actuatable to a
plurality of positions and a system for distributing a granular
product on a roadway within a range of distribution rates; a first
sensor providing a first signal corresponding to the position of
the snowplow, a second sensor providing a second signal
corresponding to the distribution rate of the product, a third
sensor providing a third signal corresponding to the position of
the vehicle, and a clock providing a time signal; and electronic
data capturing and computational module that receives the first
signal, second signal, third signal, and time signal, the first
signal and second signal being transmitted from the corresponding
said sensor to said module by communication over the power system,
said module using the second signal, third signal, and time signal
to compute a product output rate in terms of weight of product
distributed per unit distance.
18. The system of claim 17 which further comprises an automatic
vehicle locating system, wherein the computed data is provided to
the AVL system.
19. The system of claim 17 which further comprises a repeatedly
removable non-volatile memory unit, wherein the computed data is
provided to the unit.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of priority to U.S.
Provisional Patent Application Ser. No. 60/880,901, filed Jan. 17,
2007, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention pertains to electrohydraulic control
systems for vehicles, including such systems that can be
retrofitted onto an existing vehicle, and also including systems
for control and removal of ice and snow.
SUMMARY OF THE INVENTION
[0003] One embodiment of the present invention pertains to
improvements in the operation of snowplows, including the
conversion of existing snowplows to include electronic control
systems.
[0004] Yet another embodiment pertains to an apparatus for
controlling a snowplow of a vehicle, comprising a hydraulically
actuatable snowplow, a hydraulic actuator, an electronic
controller, and dual input devices including a hand stick and a
keypad.
[0005] Yet another embodiment pertains to an apparatus for
controlling the snow removal functions of a vehicle, comprising a
vehicle including a hydraulically actuatable snowplow and other
actuatable tools, and a dual axis joystick with switches for
establishing which tool is controlled by the joystick.
[0006] Yet another embodiment pertains to a method for controlling
the snowplow of a truck, comprising a truck having an actuatable
snow removal tool and a two axis controller, wherein the tool
responds to the controller with a predetermined rate of
movement.
[0007] Yet another embodiment pertains to a system for
electronically logging the snow and ice removal functions for the
vehicle, in which the vehicle includes a snowplow and a system for
distributing a granular product on a roadway. The system further
includes sensors pertaining to the snowplow and distribution
system. The system further includes an electronic controller that
receives the sensor signals, as well as other information about the
state of the vehicle, this data being communicated to the
controller over the vehicle power system. The controller compute
data from this sensed data pertaining to the snow and ice removal
functions of the vehicle, and makes that computed data available to
a memory until or an AVL system.
[0008] In yet another embodiment of the present invention, there is
an vehicle that has an electrohydraulic control system that permits
the user to operate one or more snow and ice removal functions. The
electronic controller of the system includes an algorithm that
modifies the electrohydraulic control functions based on whether a
particular tool uses a single acting or double acting hydraulic
cylinder. In particular, another embodiment pertains to existing
vehicles that have been retrofit with a kit, and this feature
permits a single set of control algorithms to be used with
different hydraulic actuators.
[0009] Yet another embodiment of the present invention pertains to
a vehicle that includes a system for removing snow and ice from a
roadway. Preferably, the computer receives a signal corresponding
to road temperature. The algorithm can adjust the rate at which a
granular product (such as salt) is applied to the roadway based on
the roadway temperature. As one example, the rate at which the
spreader applies the granular product to the roadway increases with
decreasing temperature. In one embodiment, this relationship is
linear.
[0010] It will be appreciated that the various apparatus and
methods described in this summary section, as well as elsewhere in
this application, can be expressed as a large number of different
combinations and subcombinations. All such useful, novel, and
inventive combinations and subcombinations are contemplated herein,
it being recognized that the explicit expression of each of these
myriad combinations is excessive and unnecessary.
DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a top, right, and rear photographic representation
of a vehicle 20 according to one embodiment of the present
invention.
[0012] FIG. 2 is a left and rear photographic representation of a
vehicle 20 according to another embodiment of the present
invention.
[0013] FIG. 3 is a schematic representation of a vehicle control
system according to another embodiment of the present
invention.
[0014] FIG. 4 includes three mutually orthogonal views of an
electrohydraulic interface unit 60 according to one embodiment of
the present invention.
[0015] FIG. 5 is a frontal view of a keypad 80 according to one
embodiment of the present invention.
[0016] FIG. 6 is a perspective photographic representation of a
joystick 70 according to one embodiment of the present
invention.
[0017] FIG. 7 is a table describing the valves, hydraulic
actuators, and tool functions of a vehicle according to one
embodiment of the present invention.
[0018] FIG. 8 is a wiring diagram according to one embodiment of
the present invention.
[0019] FIG. 9 is a schematic representation of a portion of a
vehicle control system according to one embodiment of the present
invention.
[0020] FIG. 10 is a schematic representation of a portion of a
vehicle control system according to one embodiment of the present
invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] For the purposes of promoting an understanding of the
principles of the inventions, reference will now be made to the
embodiments illustrated in the drawings and specific language will
be used to describe the same. It will nevertheless be understood
that no limitation of the scope of the inventions is thereby
intended, such alterations and further modifications in the
illustrated device, and such further applications of the principles
of the inventions as illustrated therein being contemplated as
would normally occur to one skilled in the art to which the
inventions relate.
[0022] Various embodiments of the present invention pertain to
improvements in the operation of electrohydraulic controls systems
on a vehicle such as a truck. In particular, some embodiments
pertain to trucks outfitted as snowplows, although other
embodiments pertain to vehicles with various movable
electrohydraulically actuated tools.
[0023] One aspect of the present invention pertains to a power
distribution system intended to provide control over the electric
portion of a medium or large hydraulic scheme. The system 40 will
consist of a control panel and power distribution units. Depending
upon the application, up to three power distribution units 50
provide control to various hydraulic components.
[0024] The control panel will communicate with one master power
distribution unit using PLC (Power Line Carrier) technology.
Examples of this technology include power systems in compliance
with SAE Standard J1939, SAE Standard J1708, or RS-485. These
standards are by example only, and are not intended to be limiting.
Additional power distribution units will communicate with the
master over a serial interface.
[0025] PLC technology can send control commands or sensory data
through the vehicle voltage/ground connections anywhere upon the
chassis. It can be used on applications that otherwise would
require multi-conductor connections via traditional wiring
harnesses. It can also have a positive impact on applications that
require plurality in control locations. Multiple controls can be
connected to the power/ground "bus" simultaneously or a single
control can be plugged into "stations" throughout the vehicle.
These could be cigarette lighter powerpoints. Applications
involving trailers that would otherwise need multiconductor plug
connections from truck to trailer greatly benefit. A datastream is
superimposed on the electrical system at high frequency. Data is
guarded against interference by constant frequency shifting and
using digital protocols for collision resolution systems that
establish priorities for data "crosstalk."
[0026] One embodiment of the present invention includes lighting
controls and joystick cylinder control. A radio or modem
transmitter sends real time location and application data to a
dispatcher. A GPS receiver tracks the actual truck location. The
use of pressure compensated hydraulics avoid the "Dead Stick."
Electronically controlled downside pressure extends blade life.
Electronic spreader controls automatically control application rate
based on ground speed. Data loggers keep track of changes that the
driver makes. A road and air temperature sensor interface is
included. Some embodiments of the present invention utilize one or
both of these temperature signals in a spreader control algorithm.
Electronic encoders for material control are used. In yet other
embodiments the output of the encoders is used only for recording
purposes. In yet other embodiments material control is accomplished
in accurate form with linear proportional hydraulic valve. A
Pre-Wet Liquid applicator sprays granular product with advanced
agents.
[0027] One aspect of the present invention pertains to
electrohydraulic control systems 40 that can be retrofitted onto
existing vehicles. The vehicles have one or more tools that use
hydraulic power, such as a plow 22 or dump body 26. An operator
inside the vehicle actuates the tools to a given position or to
operate at a given speed. Further, it is understood that other
types of hydraulically controlled tools are contemplated, including
wing plows 24, gratings or grizzlies 28, tailgate augers 30,
spinner 32, conveyor drives 34, spinner drives 36, and front and
rear loading buckets. These tools are by example only, and are not
intended to be limiting.
[0028] In some embodiments, the cab of the vehicle 20 includes both
a joystick-type controller 70 and a keypad controller 80.
Preferably, both the joystick 70 and the keypad 80 can be used to
operate some of the same tools. As one example, movement of the
joystick by the operator commands a tool to move at a rate or
velocity that is proportional to the distance and direction that
the joystick has moved. As another example, the keypad can control
movement of the same tool in the same directions, but at a rate
that is fixed. The fixed, predetermined rate is implemented as an
operator command upon movement of a switch from one position to
another position.
[0029] In one embodiment, the joystick 70 includes a plurality of
buttons 72, 73, and 74 by which various tools of the vehicle can be
actuated. In one embodiment, buttons 72, 73, and 74 are provided
for controlling the plow, scraper, and dump body, respectively. The
vehicle operator selects between plow, dump or scraper operation by
momentarily pressing the appropriate button on the joystick head.
The selection will be locked in and displayed on the control panel
with a lighted label (Plow, Dump, Scraper). However, the buttons of
the joystick can be associated with control of any tool, and are
not limited. Further, joystick 70 preferably includes a deadman
button 71 which provides safe operation of the vehicle control
system as described later herein.
[0030] In some embodiments, one of the data signals from either the
joystick 70 or the keypad 80 is converted by an electrical
interface unit 50 to a command signal. Preferably, this command
signal is transmitted over a vehicle power bus to an
electrohydraulic interface unit 60. Unit 60, in some embodiments,
receives hydraulic fluid under pressure from a pump operated by a
power take-off unit receiving power from the vehicle
drivetrain.
[0031] The spreader or spinner 32 and its associated drive 36 are
controlled with a variety of different programmed functions. The
spreader on-off is controlled by simultaneously pushing auger and
liquid knobs together. The spreader functions include:
[0032] (1) Auto-Man, Blast & Pause Operation:
[0033] The operator selects Auto or Manual operation by pressing
the Liquid control and holding for two seconds and then releasing
to see the change. Blast operation is initiated by pressing and
releasing the Auger control knob. Blast will last a predetermined
time and then normal spreader operation will resume. Pause
operation of the spreader is initiated by pressing and releasing
the Spinner control knob. Pressing and releasing the Spinner
control knob again resumes spreader operations.
[0034] (2) Granular Product Selection Operation:
[0035] Up to 3 different granular material products can be selected
for calibrated operation. These are designated Prod 1, 2 & 3 by
the system. To change a Product selection, the operator holds the
Spinner knob before the Spreader function is turned-on, and
slightly turns the knob either direction. The display shown will
appear. While holding the Spinner knob down, the operator turns it
either direction to the desired Product number and then releases
it.
[0036] (3) Auto Spreading Operation:
[0037] The operator pushes and holds the Liquid control for two
seconds and releases it to switch from Man to Auto. The AUTO label
flashes whenever the MPH is "0" or there is no speedometer
connection. This also indicates the auger is not turning. The
operator selects an Auger output by turning the Auger control to
increase or decrease the display from "00" to "99". If the system
has been weight calibrated, then the number displayed times 10
indicates the "LBS PER MILE" to be spread in Auto. (Ex. Display
47.times.10=470 LBS/MILE). If the system has not been weight
calibrated, then the operator adjusts the Auger control setting
while observing the spread pattern in the mirrors. The Auto
function will still adjust itself to produce the same pattern at
all MPH.
[0038] (4) Manual Spreading Operation:
[0039] The operator pushes and holds the Liquid control for two
seconds and releases it to switch from Auto to Man. The operator
then adjusts the Auger control for "00, 10, 20, 30 . . . 90, 99" on
the display. These are reference values. The operator make an
adjustment while observing the pattern in the mirrors. The setting
results in a constant auger speed regardless of MPH. The operator
uses the PAUSE function to stop and start at intersections,
etc.
[0040] Preferably, the vehicle power bus 38 is a 12 volt DC bus,
and the command signal is represented at one or more frequencies
superimposed on the 12 volt DC bus, such as a powerline
communication (PLC) signal transmitted in accordance with SAE
#J1959. Interface module 50 is capable of receiving multiple
command signals, multiplexing the signals onto the power bus, and
demultiplexing these various command signals to produce individual
actuation signals. It is understood that various embodiments of the
present invention include one or more electronic control and/or
data-logging modules. These electronic units are interchangeably
referred to as modules, units, and controllers. It is understood
that the functions of such devices can be included in a single
physical unit or multiple physical units, on a single circuit board
or on multiple circuit boards.
[0041] Electrohydraulic interface unit 60 receives the
demultiplexed actuation signals and provides those signals to
corresponding electrohydraulic converter mechanisms. As one
example, hydraulic interfacing at 60 includes at least one
converter that includes a proportional cylinder that applies a
force to a corresponding spool valve, the force being in proportion
to the actuation signal. The spool valve responds to this force by
providing hydraulic fluid to an actuation such as a piston and
cylinder actuation that is coupled to the tool. The spool valve
provides hydraulic fluid to the actuation at a commanded flow rate
or at a commanded pressure.
[0042] Some embodiments of the present invention include a safety
algorithm that monitors communication on the PLC power/databus. The
primary electronic control unit receives command signals from the
joystick and keypad, and transmits command signals via the
power/databus to one or more distributed electronic controllers
located remotely in the vehicle. A remote, distributed controller
receives the command, and provides the appropriate command output,
such as a current drive signal, to the electrohydraulic control
valves. The distributed controller monitors communication traffic
on the power/databus, and is programmed to receive messages four
times per second. Between messages, the distributed controller
(MPDU) latches its command output to the last command state. If a
predetermined number of messages are missed by the distributed
controller, then the distributed controller interrupts all outputs
to provide safe operation. In one embodiment, the predetermined
number of missed messages is four. In addition, if there is loss of
PCL communication, the primary electronic controller will provide a
visual indication at the control panel display for loss of PLC
communication. As one example, the touch pads of the display do not
change from green to red when buttons are pushed, and instead
remain green.
[0043] FIGS. 3, 9, and 10 refer to a schematic representation of a
vehicle control system according to one embodiment of the present
invention. Referring first to FIG. 9, some embodiments of the
present invention further include a sensor system 90 which includes
a plurality of sensors and switches 92, signals from which are
received by a sensor input module 94. Module 94 is in communication
via power bus 38 with a data capture module 96 that suitably
converts the sensor data and provides it to an RS232 databus, to a
memory device 98 to other portions of the control system 40. In one
embodiment, sensor sweet 92 includes sensors and switches that
provide signals corresponding to the following quantities: liquid
flow turbine, hydraulic motor encoder, hydraulic pressure, gate
elevation, oil temperature, oil level, filter bypass, no liquid, no
material, dump up, scraper down, wing down, and plow down.
[0044] As best represented in FIGS. 3, 9, and 10, some embodiments
of the present invention include a data logging system, which
includes means for storing sensor data in a readily retrievable
format, and also means for transmitting data to an automatic
vehicle located (AVL) system. The data logging system preferably
includes a base data-capture and memory storage system 98, and a
databus, such as an RS-232 databus for streaming data serially to
an AVL system. The data logging system further includes a sensor
input module 94 and a sensor display 100 for the operator.
[0045] Data capture module 96 captures data representative of the
state of the vehicle (velocity, odometer reading, position, etc.)
and also the setting of the control system. Preferably, the data
captured in the data logging system includes: granular output rate
setting (LBS/MILE in real time); granular product selection (PROD
1-3 in real time); truck speed (MPH in real time); liquid output
rate setting (CONTROL PERCENTAGE in real time); spinner control
setting (PERCENTAGE in real time); blast (ON in real time); pause
(ON in real time); and totals per calendar day and per granular
product selection (PROD 1-3), including, total granular weight per
product; total granular miles; total granular minutes; total
granular blast weight; total granular blast miles; total liquid
minutes; and total liquid miles.
[0046] The data logging system further includes a real time clock
embedded in the module. The day-date is appended to each of the
"Total" files described above. The module's memory storage is a
"thumb drive" other non-volatile, easily removable transportable
memory device allowing easy transfer of data to a personal
computer. Calibrations from the "as is" system are copied to the
thumb drive. A truck identity is associated to the data files. The
module will preferably be located in the truck cab. The data format
is preferably stored as a comma delimited string. A serial
communication capacity is used with AVL systems. Data transfer of
the "Real Time" values described above can occur by a query
protocol and/or by constant output stream of at least once per
second.
[0047] In some embodiments, the data capture module is a module
located in the hydraulic valve compartment that reads a variety of
sensors and switches 92 that are in electrical communication with
it, either via the PLC or via hardwire. It makes the sensor
information available for extended data-logging fields and for
display to the operator. Some of the data available includes:
hydraulic oil temperature, hydraulic oil level, filter bypass, road
temperature, air temperature, hydraulic pressure, spreader
material, gate elevation, plow down, wing down, and scraper down.
Preferably, the data stored and made available for transmission by
the data logging system complies with governmental specifications,
including specifications by the Administrative Transportation of
Ontario Province, Canada.
[0048] Preferably, the control module further reacts to out of
range values for various levels of input data. As one example, if a
sensor 92 indicates that the hydraulic oil level is low, then
controller module 50 disengages (by relay) the appropriate
hydraulic pumps or shifts the appropriate diverter valve.
[0049] In one embodiment, the present invention includes a display
such as an LCD display mounted within site of the vehicle operator.
Display 100 includes indicator lights with digital representations
or analog representations from the sensor system 90. Various
warning levels will be associated with many of the sensor signals
and switch positions, and display 100 will preferably indicate any
perimeters outside of these limits by various visual or audible
flags. Further, in one embodiment, the display is a touch screen,
and the vehicle electronic system includes an algorithm for
programming critical temperatures of road temperature and air
temperature. Exceeding these ambient conditions also result in
actuation of a visual or audible alarm.
[0050] Although details of various features of the control system
are shown and described, it is understood that these are only by
example, and are not limiting to the inventions. As one example, a
control system according to another embodiment of present invention
can be implemented on new vehicles as OEM equipment. In yet other
embodiments the operator inputs can include, instead of a joystick,
any type of switching device that can be moved in a direction over
a range of positions, including slide switches and rotary switches.
In yet other embodiments, keypad 80 can include, rather than manual
switches, a touch screen or voice-activated functions. In yet other
embodiments where the vehicle tools are pneumatically operated,
there would also be a corresponding electropneumatic interface unit
replacing the electrohydraulic interface unit. Further, other
embodiments of the present invention contemplate the use of
dedicated communication buses, rather than using commands
implemented via PLC on a power bus.
[0051] The following pages will describe other elements, features,
and aspects of different embodiments of the present invention. It
is understood that all of the descriptions herein are by example
only, and are not intended to be limiting.
[0052] In some embodiments of the present invention the system
controls pertain to:
[0053] Cab-to-Valve Connection: Commands from the system controls
to the system valves are preferably digitally encoded and sent over
the vehicle electrical system using only a 12VDC and Ground
connection at each end of the system.
[0054] Valve Driver Modules: The valve driver modules are
preferably housed in Deutsch boxes and employ Deutsch connectors at
the solenoids giving IP69 environmental rating.
[0055] The Driver Modules are preferably equipped with current
sensing control to (1) offset thermal changes in solenoid
performance, (2) to detect open or short circuit conditions and
protect against the latter by automatic interruption of current to
the shorted output.
[0056] Cylinder Controls (Pushbutton) via Keypad 80: Momentary
pushbutton switches will provide on-off style control of the plow
and dump body operations. Program settings will provide effective
and independent flow trims for plow up-down, plow angle and dump
up-down.
[0057] Cylinder Controls (Joystick 70): A two axis proportional
joystick with deadman switch and pushbutton selection of equipment
(i.e. Plow, dump hoist, etc.) are preferably provided. The joystick
employs dual redundant hall-effect mechanisms, minimizing the wear
of potentiometer or other contact mechanisms. In the event of
failure of one hall-effect output a program adjustment to the
system Controller will allow selection of the alternate channel.
The same Controller will also provide electronic adjustment of: (1)
degrees from center for operation (deadband), (2) minimum valve
drive at minimum joystick deflection, (3) maximum valve drive at
maximum joystick deflection. Adjustments 2 & 3 will be
independent for each the plow and dump. The joystick plug to the
control panel as its only connection point. Connection of the
joystick will render the pushbutton cylinder controls inoperable.
Conversely, disconnection of the joystick will reactivate the
pushbutton controls. Selection of equipment function by pushbuttons
on the head of the joystick will illuminate an equipment identity
label on the control panel. No operation of the joystick can take
place without holding the deadman switch.
[0058] To disable the pushbuttons, press the plow up and down
simultaneously and hold for 5 seconds. The keypad lighting will
switch from green to red. The buttons will remain red but will not
operate. Repeat holding the plow up and down to reinstate the
controls. To disable the joystick hold the plow and scraper
selection buttons simultaneously for 5 seconds. The Plow, Dump and
Scraper labels on the panel will go off. The joystick is now dead.
Repeat the sequence to reinstate joystick control.
[0059] In some embodiments of the present invention the spreader
controls pertain to:
[0060] a) Modes of Operation: Automatic and Manual control are
preferably selectable.
[0061] b) Pause & Blast: There are preferably a Blast operation
with programmable selection of level and time. A Pause operation
are preferably available to momentarily disable the spreader
operation.
[0062] c) Open-Loop Servo: A feedback sensor is not required to
achieve accurate and consistent operation of the spreader
functions.
[0063] d) Displays 86, 87, 88: High brightness LED numerical
displays will be used to indicate one of 11 reference control
positions for the spinner and auger (manual mode). In Auto
operation the auger display will indicate "pounds per mile" if the
system has been calibrated for such.
[0064] Fault Displays: The system displays occurrences of shorted
or open outputs at the valves with indication of which circuit is
responsible.
[0065] Liquid Operation: The system includes control for the
operation of a pre-wetting liquid function. The control of this
function are preferably operable as a groundspeed proportional
output or as a strictly manual control. A LED numerical display
will indicate the output of this system by reference numbers. The
Liquid Pre-wet On-Off is controlled by simultaneously pushing the
Liquid and Spinner knobs together.
[0066] Some embodiments of the present invention include a software
algorithm in the vehicle's computer controller that adjusts the
spreader control based on road temperature when the spreader
control is in the AUTO mode. The algorithm would vary the auger
rate as a percentage of its operation in accordance with the
variance of road temperature about a target value. The percentage
of change can be set by the user, as well as the target value of
road temperature, and the upper and lower limits on road
temperature. In one embodiment, the change in auger operation is
linearly related to variation and road temperature. Preferably, the
slope of this relationship is in the range of about 0.5
percent/degree to about 2 percent/degree. As one example, the
desired auger output (expressed as 100 percent) would be
established at a target temperature such as 27.5 degrees F. For
each degree that road temperature is below 27.5 degrees, the output
of the auger is changed (preferably raised) about 1 percent.
[0067] In some embodiments of the present invention the control
definitions pertain to:
[0068] Cylinder operations: Momentary pushbutton control.
[0069] Auger/Spinner operations: Rotary control input with marked
positions or momentary increase/decrease pushbutton and with a
numerical or bargraph indicator of output magnitude.
[0070] Blast operation: A momentary pushbutton that increases the
auger drive to maximum while depressed and maintains that operation
after release for an adjustable time delay of 0-30 seconds.
[0071] Pass or Pause operation: A momentary pushbutton that
interrupts the spreader operation while depressed.
[0072] Spreader On/Off: Alternate push on/push off control of the
spreader operation. The Spreader On/Off is controlled by
simultaneously pushing the Auger and Liquid knobs together.
[0073] Auto/Manual Spreader operation: Alternate pushbutton
selection of Auto (groundspeed proportional) operation of the
spreader or Manual (no groundspeed proportioning). Automatic
operation should automatically drop the auger and spinner drives at
0 MPH.
[0074] Pre-Wet operation: Pushbutton On/Off control. Momentary
pushbuttons or rotary controls for increasing and decreasing the
motor/pump speed. Similar to the spreader controls. If pushbuttons
are used then a numerical or bargraph display of the drive
magnitude is required. The pre-Wetting drive is proportional to the
vehicle speed. The pre-wetting systems includes one or more tanks,
spray bars, and pumps for pre-wetting the granular material.
[0075] Controls Summary: the control system preferably includes
capability to perform the following functions: Spreader On/off,
Auger increase/decrease, Spinner increase/decrease, Blast, Pass or
Pause, Plow raise, Plow lower, Plow left, Plow right, Dump raise,
Dump lower, Pre-Wet On/off, and Pre-Wet increase/decrease. The Plow
and Dump Keypad On-Off is controlled from the ignition on-off.
[0076] Adjustability/Programmability: Operating parameters such as
the spreader minimum/maximum trims described before and others
described below can be adjusted in the user calibration program.
The operating parameters include: Spreader valve minimum/maximum
trims, Pre-Wet motor minimum/maximum trims, Blast time-out delay,
Speedometer input calibration, and Single/Double acting cylinder
operations (as indicated in FIG. 7).
[0077] Control system 40 includes a plurality of different
adjustment capabilities. To enter the adjustment mode, with the
spreader control off--the operator presses the Auger and Spinner
knobs together and holds for two seconds. After the controller
powers up in the Adjustment Mode (CA), the operator enters a Pass
Code using the Liquid and Spinner displays and knobs (pressing the
Spinner knob to enter the value). If the wrong value is entered,
the screen will go blank.
[0078] The user scrolls through the menu of keypad 80 in the
following manner. After entering the proper passcode the first line
of the menu of adjustments will appear as shown. The user may
scroll through the menu items by turning the Auger control knob.
The menu items preferably include the following:
[0079] Auger (Min) Lo and Auger (Max Hi): Auger LO sets the lowest
speed available to the operator. It should be high enough to cause
the Auger or Conveyor to turn. The operator turns the Spinner knob
to adjust the value and then presses to enter. Auger HI sets the
highest speed available to the operator. The operator turns the
Spinner knob to adjust the value and then presses to enter.
[0080] Spinner (Min) Lo and Spinner (Max Hi): Spinner LO sets the
lowest speed available to the operator. It should be set high
enough to cause Spinner movement. The operator turns the Spinner
knob to adjust the value and then presses to enter. Spinner HI sets
the highest speed available to the operator. The operator turns the
Spinner knob to adjust the value and then presses to enter.
[0081] Liquid (Min) Lo and Liquid (Max) Hi: Liquid LO sets the
lowest output flow available to the operator. It should be set high
enough to cause some flow. The operator urns the Spinner knob to
adjust the value and then presses to enter Liquid HI sets the
highest output flow available to the operator. The operator turns
the Spinner knob to adjust the value and then presses to enter
[0082] Blast Timer and Level Settings: Blast (to) sets the Time-Out
function on Blast operations. This can be set for 0-30 seconds of
operation after the Blast button is released. The operator uses the
Spinner knob to select and pushes to enter the value. Blast HI sets
the Auger or Conveyor speed for the Blast operation. This can be
0-99% of full capacity. The operator uses the Spinner knob to
select and pushes to enter the value.
[0083] Speedometer Input Type: GS or Groundspeed is asking for the
type of speedometer input. The user is presented with options for
choosing the type of transmission provided in their vehicle, such
as for Allison or International Transmissions.
[0084] Speedometer MPH Matching: GS CA is the Groundspeed
Calibration. It is used to synchronize the control system to the
truck. The operator adjusts the Spinner display to a target MPH,
drives the truck until the target speed is reached, and holds
steady. The operator then pushes the Spinner knob while the truck
is at the target speed and checks the results by slowing and
reaccelerating. The Spinner display will blink and an audible tone
will be heard when the speed matches again.
[0085] Weighted Dump Calibration: The operator fills the truck with
material, weighs it, and positions the truck to discharge material.
The hydraulic pump should be operating and the engine speed should
be at least 1500 RPM. The operator sets the Auger (rt) rate on the
Spinner display to a mid-level value (30-70) and presses the
Spinner knob to start the dump process. The operator then pushes
the Spinner knob again to stop the dump process, reweighs the truck
and subtracts from the first weight to determine the dumped pounds
of material. The operator enters the dumped pounds using the Liquid
and Spinner knobs and displays and pushes the Spinner knob to enter
the value.
[0086] Plow and Dump Cylinder Type: If the Plow lift cylinder is
single-acting set the Spinner display for 1. If it is a
double-acting cylinder set it for 0. Press the Spinner knob to
enter the value. If the Dump hoist cylinder is single-acting set
the Spinner display for 1. If it is a double-acting cylinder set it
for 0. Press the Spinner knob to enter the value. The valves of the
electrohydraulic control unit are configured in advance for single
or double acting cylinder operations. This program selection allow
for the microcontroller to apply hydraulic power for retraction of
double acting cylinders, or not apply hydraulic power for
retraction of single acting cylinders (i.e., gravity down).
[0087] Plow (Min) Lo and Plow (Max Up and Down) dr: For Joystick
users, the Plow LO and (dr) will set the low and high Plow (up
& down) flows for the travel of the Joystick. The operator sets
each on the Spinner display and pushes the Spinner knob to enter
the values. For Keypad users, the Plow LO serves no function and
can be ignored. The Plow (dr) "drive" will allow trimming the flow
or speed of the Plow (up & down) operation when those keypads
are pressed. The operator sets a value on the Spinner display and
pushes the Spinner knob to enter.
[0088] Plow Angle (Max left & right) dr: This setting allows
for trimming the speed of the angle operation when the joystick is
full left or right. It also determines the speed of the angle
operation when the left and right arrowed pushbuttons are used on
the keypad control. The operator adjusts the value in the Spinner
window with the Spinner knob and pushes the Spinner knob to install
the setting into the system.
[0089] Dump (Min Lo and Dump (Max) dr: For Joystick users, the Dump
LO and (dr) will set the low and high Dump flows for the travel of
the Joystick. The operator sets each on the Spinner display and
pushes the Spinner knob to enter the values. For Keypad users, the
Dump LO serves no function and can be ignored. The Dump (dr)
"drive" will allow trimming the flow or speed of the Dump operation
when those keypads are pressed. The operator sets a value on the
Spinner display and pushes the Spinner knob to enter.
[0090] Joystick Deadband: This adjustment will determine the
sensitivity of the Joystick as it is moved off center. The operator
sets the Spinner display for 0-5 to determine how far from center
the Joystick should be moved before operation begins.
[0091] Backup Joystick Channels (Up and Down) The joystick has the
feature of having two sets of output mechanisms. If the primary
channel fails the operator has the recourse of switching to the
backup channel to "repair" the joystick. If the operator loses
operation on the raise-lower function "Fb" (forward-back) he can
select "channel 1" to restore function. "Channel 0" is the factory
default or primary. The operator uses the Spinner knob, displays to
change channels, and pushes the spinner knob after the selection to
lock it in.
[0092] Backup Joystick Channels (Left an Right): A backup channel
is also assigned to the left-right function of the joystick. (See
preceding instruction) The operator selects "channel 1" if
experiencing a problem with the left-right joystick operation.
"Channel 0" is the factory default and primary channel. The
operator uses the Spinner knob, displays to change to "channel 1,"
and locks in the setting by depressing the Spinner knob.
[0093] Product 2 and 3 Weight Ratios: The product used to perform
the Weighed-dump calibration is Product 1 and is the reference
product. The weight ratio of Product 2 and Product 3 as compared to
Product 1 can be entered as a percentage 50-150% on the Spinner
display and entered by pushing the Spinner knob. Example: If the
weight of Product 2 is half of Product 1 enter 50. If Product 3 is
20% heavier than Product 1, enter 120.
[0094] Auto Mode Take Off Timer The AUTO mode has a (to) take-off
timer that will cause the Auger speed to operate at the Blast level
for however many seconds have been set on this feature whenever the
truck starts from 0 MPH. The operator sets the Spinner display for
0-9 seconds and pushes the Spinner knob to enter the value.
[0095] In some embodiments of the present invention the functional
description pertains to:
[0096] Control Panel 80 The panel will control outputs at power
distribution units, display measurements and settings, provide
diagnostic feedback, and allow access to the calibration menu. The
following items describe the inputs, outputs, and functionality of
the control panel.
[0097] AUGER label backlight 86--yellow; Illuminates yellow when
power is supplied to the control panel, remains on when the
spreader is turned on. Illuminates yellow and flashes if the auger
output is open, or the rated current for the auger output has been
exceeded.
[0098] LIQUID label backlight 87--yellow: Illuminates yellow when
power is supplied to the control panel, remains on when the
spreader is turned on. Illuminates yellow and flashes if the liquid
output is open, or the rated current for the liquid output has been
exceeded.
[0099] SPINNER label backlight 88--yellow: Illuminates yellow when
power is supplied to the control panel, remains on when the
spreader is turned on. Illuminates yellow and flashes if the
spinner output is open, or the rated current for the spinner output
has been exceeded.
[0100] Auger Rate Display 86--Red seven segment: Spreader Auto
Mode--Displays the auger dispense rate in 10*lbs/mile. The
displayed value will range from 00 to 80 with a resolution of 05.
Spreader Manual Mode--Displays reference value that corresponds to
the auger dispense rate. A reference value of 10 will correspond to
the auger minimum trim value, while a value of 99 will correspond
to the auger maximum trim value. The displayed value will range
from 00 (off) to 99 (maximum trim) in increments of 10.
[0101] Liquid Rate Display 87--Red seven segment: Displays
reference value that corresponds to the liquid dispense rate. A
reference value of 10 will correspond to 10/100*auger reference
value*trimmed liquid range, while a value of 99 will correspond to
99/100*auger reference value*trimmed liquid range. The displayed
value will range from 00 (off) to 99 (maximum trim) in increments
of 10.
[0102] Spinner Rate Display 88--Red seven segment: Displays
reference value that corresponds to the spinner dispense rate. A
reference value of 10 will correspond to the spinner minimum trim
value, while a value of 99 will correspond to the spinner maximum
trim value. The displayed value will range from 00 (off) to 99
(maximum trim) in increments of 10.
[0103] Auger Rate Knob 81--Rotary encoder with spst pushbutton:
Simultaneously pressing the auger rate knob along with the liquid
rate knob will enable the auger and spinner outputs (spreader).
Upon enabling the auger and spinner, the auger rate display and
spinner rate display will turn on at a value of 00 (off). Upon
being enabled, the auger and spinner outputs will correspond to the
display readings and will be off.
[0104] Pressing the auger rate knob will set the auger output to
the "blast level" as defined in the calibration settings. The auger
rate display will display "bL" during a blast event. The blast
level will be maintained for as long as the button is depressed,
and will continue after the button is released for the "blast time
out" period as defined in the calibration menu. During a blast
event, if the auger rate knob is pressed before the "blast time
out" period has expired, the blast event will be interrupted, and
the auger will return to the pre-blast value.
[0105] Spreader Auto Mode--Turning the auger rate knob clockwise
will increase the dispensed material rate in 50 lbs/mile
increments. The auger output will supply the current to dispense
the displayed rate output. When the maximum value of 800 lbs/mile
is reached, the rate value will remain at 800 regardless of further
clockwise turns. Turning the auger rate knob counterclockwise will
decrease the dispensed material in 50 lbs/mile increments. When the
minimum value of 00 lbs/mile is reached, the value will remain at
00 regardless of further counterclockwise turns.
[0106] Spreader Manual Mode--Turning the auger rate knob clockwise
will increase the displayed reference value in increments of 10.
The auger output will provide output current corresponding to the
reference value. When the maximum value of 99 is reached, the value
will remain at 99 regardless of further clockwise turns. Turning
the auger rate knob counterclockwise will decrease the reference
value in increments of 10. When the minimum value of 00 is reached,
the value will remain at 00 regardless of further counterclockwise
turns.
[0107] With the spreader enabled, simultaneously pressing the auger
rate knob along with the liquid rate knob will disable the auger
and spinner outputs (spreader). If enabled, the liquid output will
also be disabled. The auger, liquid and rate displays, will turn
dark.
[0108] Liquid Rate Knob 82--Rotary encoder with spst pushbutton:
Simultaneously pressing the liquid rate knob along with the spinner
rate knob will enable the liquid output. The liquid rate display
will turn on with a value of 00 (off). Upon being enabled, the
liquid output will correspond to the display reading and will be
off. If the spreader is off, pressing the liquid and spinner rate
knobs will not enable the liquid output, and the liquid display
will remain dark.
[0109] Pressing and releasing the liquid rate knob will toggle the
mode of the spreader between the "AUTO" and "MANUAL" settings. The
switch should be depressed and held for >1 sec to change
settings.
[0110] Turning the liquid rate knob clockwise will increase the
displayed liquid reference value in increments of 10. When the
maximum value of 99 is reached, the value will remain at 99
regardless of further clockwise turns. Turning the auger rate knob
counterclockwise will decrease the reference value in increments of
10. When the minimum value of 00 is reached, the value will remain
at 00 regardless of further counterclockwise turns. The liquid
output provides output current that is a percentage of the trimmed
liquid output range equal to the liquid reference
value/100*reference auger value.
[0111] With the liquid output enabled, simultaneously pressing the
liquid rate knob along with the spinner rate knob will disable the
liquid output. When disabled, the liquid rate display will turn
dark.
[0112] Spinner Rate Knob 83--Rotary encoder with spst pushbutton:
Turning the spinner rate knob clockwise will increase the reference
value in increments of 10. The spinner output will provide output
current corresponding to the reference value. When the maximum
value of 99 is reached, the value will remain at 99 regardless of
further clockwise turns. Turning the auger rate knob
counterclockwise will decrease the reference value in increments of
10. When the minimum value of 00 is reached, the value will remain
at 00 regardless of further counterclockwise turns.
[0113] Pressing and releasing the spinner rate knob will pause the
spreader, causing the auger, liquid, and spinner outputs to turn
off. The auger rate, liquid rate, and spinner rate displays will
display PA US E. Once paused, pressing the liquid rate knob again
will un-pause the spreader, returning the auger, spinner, and
liquid outputs to their pre-pause values.
[0114] With the spreader off, pressing, holding and turning the
spinner rate knob, will allow the user to select the dispense
product as 1, 2, or 3. The button should first be pressed for >1
second. PR 0d will be displayed in the auger rate and liquid
display's along with the current product 01, 02, or 03 in the
spinner rate display. Turning the spinner rate knob will cycle
through the 3 values. Upon selecting the desired value, and
releasing the button, the new product will be used, and the display
will return to previous settings. Product ratio 1 will be 1:1 with
the calibrated dispense rate, product ratio 2 and 3 will be the
ratio entered in the respective calibration menu items.
[0115] AUTO label backlight--yellow: Illuminates yellow when the
spreader is in automatic mode with groundspeed signal. Automatic
mode is the default spreader mode upon power up. Flashes yellow
when the spreader is in automatic mode with no groundspeed
signal.
[0116] MAN label backlight--yellow: Illuminates yellow when the
spreader is in manual mode.
[0117] PLOW label backlight--yellow: Illuminates yellow when the
joystick is in the plow mode. Plow mode is the default joystick
mode upon power up. Illuminates yellow and flashes if a plow output
is open, or the rated current for a plow output has been
exceeded.
[0118] DUMP label backlight--yellow: Illuminates yellow when the
joystick is in the dump mode. Illuminates yellow and flashes if a
dump output is open, or the rated current for a dump output has
been exceeded.
[0119] SCRAPER label backlight--yellow: Illuminates yellow when the
joystick is in the scraper mode. Illuminates yellow and flashes if
a scraper output is open, or the rated current for a scraper output
has been exceeded.
[0120] Plow down pushbutton 84.1--momentary spst switch: If a
joystick is present at power on, the backlight remains dark and the
pushbutton is ignored until the joystick is removed and power is
cycled.
[0121] If the button is pressed at power on, the backlight will
remain dark and the button press will be ignored until released and
pressed again. If no joystick is present at power on, the backlight
illuminates green, and the button is monitored. If pressed, the
plow down backlight changes from green to red, and a single audible
beep is generated. The plow flow control output is set to the flow
control valve drive value as defined in the calibration menu. The
unloader output is turned on, and the plow down output is turned
on. When the button is released the three outputs will turn off and
the backlight will return to green. If an open output or over
current is detected at the plow down output while the button is
pressed, the plow down output will turn off and the button
backlight will flash red and dark with audible beeps.
[0122] Plow left pushbutton 84.2--momentary spst switch: If a
joystick is present at power on, the backlight remains dark and the
pushbutton is ignored until the joystick is removed and power is
cycled. If the button is pressed at power on, the backlight will
remain dark and the button press will be ignored until released and
pressed again. If no joystick is present at power on, the backlight
illuminates green, and the button is monitored. If pressed, the
plow left backlight changes from green to red, and a single audible
beep is generated. The plow flow control output is set to the flow
control valve drive value as defined in the calibration menu. The
unloader output is turned on, and the plow left output is turned
on. When the button is released the three outputs will turn off and
the backlight will return to green. If an open output or over
current is detected at the plow left output while the button is
pressed, the plow left output will turn off and the button
backlight will flash red and dark with audible beeps.
[0123] Plow right pushbutton 84.3--momentary spst switch: If a
joystick is present at power on, the backlight remains dark and the
pushbutton is ignored until the joystick is removed and power is
cycled. If the button is pressed at power on, the backlight will
remain dark and the button press will be ignored until released and
pressed again. If no joystick is present at power on, the backlight
illuminates green, and the button is monitored. If pressed, the
plow right backlight changes from green to red, and a single
audible beep is generated. The plow flow control output is set to
the flow control valve drive value as defined in the calibration
menu. The unloader output is turned on, and the plow right output
is turned on. When the button is released the three outputs will
turn off and the backlight will return to green. If an open output
or over current is detected at the plow right output while the
button is pressed, the plow right output will turn off and the
button backlight will flash red and dark with audible beeps.
[0124] Plow up pushbutton 84.4--momentary spst switch: If a
joystick is present at power on, the backlight remains dark and the
pushbutton is ignored until the joystick is removed and power is
cycled. If the button is pressed at power on, the backlight will
remain dark and the button press will be ignored until released and
pressed again. If no joystick is present at power on, the backlight
illuminates green, and the button is monitored. If pressed, the
plow up backlight changes from green to red, and a single audible
beep is generated. The plow flow control output is set to the flow
control valve drive value as defined in the calibration menu. The
unloader output is turned on, and the plow up output is turned on.
When the button is released the three outputs will turn off and the
backlight will return to green. If an open output or over current
is detected at the plow up output while the button is pressed, the
plow up output will turn off and the button backlight will flash
red and dark with audible beeps.
[0125] Dump down pushbutton 85.1--momentary spst switch: If a
joystick is present at power on, the backlight remains dark and the
pushbutton is ignored until the joystick is removed and power is
cycled. If the button is pressed at power on, the backlight will
remain dark and the button press will be ignored until released and
pressed again. If no joystick is present at power on, the backlight
illuminates green, and the button is monitored.
[0126] If pressed, the dump down backlight changes from green to
red, and a continuous audible beep is generated. The unloader
output is turned on, and the hoist down output is set to the dump
hoist valve drive value as defined in the calibration menu. When
the button is released the two outputs will turn off and the
backlight will return to green. If an open output or over current
is detected at the hoist down output while the button is pressed,
the hoist down output will turn off and the button backlight will
flash red and dark with audible beeps.
[0127] Dump up pushbutton 85.2--momentary spst switch: If a
joystick is present at power on, the backlight remains dark and the
pushbutton is ignored until the joystick is removed and power is
cycled. If the button is pressed at power on, the backlight will
remain dark and the button press will be ignored until released and
pressed again. If no joystick is present at power on, the backlight
illuminates green, and the button is monitored.
[0128] If pressed, the dump up backlight changes from green to red,
and a continuous audible beep is generated. The unloader output is
turned on, and the hoist up output is set to the dump hoist valve
drive value as defined in the calibration menu. When the button is
released the two outputs will turn off and the backlight will
return to green. If an open output or over current is detected at
the hoist up output while the button is pressed, the hoist up
output will turn off and the button backlight will flash red and
dark with audible beeps.
[0129] Joystick 70 with pushbutton inputs 71, 72, 73, 74--A locking
connector at the back of the control panel housing will allow for
connection of a sensor such as a Penny Giles joystick part#
JC6000-XY-HMM-M-S-NL-N-STN-A30D. The joystick will allow control
over three hydraulic functions, the plow, hoist, or scraper.
[0130] At the joystick input if more than one deflection axis is
selected, the largest value will take priority, and the smaller
value will be ignored. The joystick will not respond to angle
deflection in any direction that is less than the joystick neutral
dead band range as defined in the calibration menu. During
operation of the joystick, if the user releases the dead man's
trigger, any associated output will be turned off. The joystick
should then be returned to the center position before the output
can be re-enabled by pulling the dead man trigger, and deflecting
the joystick. The joystick will be ignored unless connected to the
control panel before power is applied.
[0131] The joystick will default to PLOW control upon power up,
causing the PLOW label at the control panel to illuminate. The
trigger (dead man) switch is pulled and held while the joystick is
in the center position, or any joystick movement will be ignored.
If the trigger switch is released after the start of a joystick
movement, any output will be turned off.
[0132] Pressing 1 of the three pushbutton switches on the top of
the joystick will change the function control of the joystick. The
joystick is in the center position or the button press will be
ignored. Pressing and releasing the top right button will produce a
single audible beep and change the function control mode of the
joystick to the scraper. The scraper label on the control panel
will illuminate.
[0133] Scraper control mode--Moving the joystick away from the user
will turn on the scraper down output, and set the flow control
output current to a value corresponding to the angle deflection of
the joystick. Moving the joystick towards the user will turn on the
scraper up output, and set the flow control output current to a
value corresponding to the angle deflection of the joystick. Moving
the joystick to the left will turn on the scraper left output, and
set the flow control output current to a value corresponding to the
angle deflection of the joystick. Moving the joystick to the right
will turn on the scraper right output, and set the flow control
output current to a value corresponding to the angle deflection of
the joystick.
[0134] Pressing and releasing the bottom middle button will produce
a continuous audible beep and change the function control mode of
the joystick to dump. The audible beep will continue for as long as
the joystick is in the dump control mode. The dump label on the
control panel will illuminate. Once in the dump mode, if the
joystick remains in the neutral position for greater than 30
seconds, the mode will automatically change to plow.
[0135] Dump control mode--Moving the joystick away from the user
will set the hoist down output current to a value corresponding to
the angle deflection of the joystick. Moving the joystick towards
the user will set the hoist up output current to a value
corresponding to the angle deflection of the joystick.
[0136] Pressing and releasing the top left button will produce a
single audible beep and change the function control mode of the
joystick to plow. The plow label on the control panel will
illuminate.
[0137] Plow control Mode--Moving the joystick away from the user
will turn on the plow down output, and set the flow control output
current to a value corresponding to the angle deflection of the
joystick. Moving the joystick towards the user will turn on the
plow up output, and set the flow control output current to a value
corresponding to the angle deflection of the joystick. Moving the
joystick to the left will turn on the plow left output, and set the
flow control output current to a value corresponding to the angle
deflection of the joystick. Moving the joystick to the right will
turn on the plow right output, and set the flow control output
current to a value corresponding to the angle deflection of the
joystick.
[0138] Calibration Menu--Accessing the calibration menu will the
completion of a startup sequence and entry of a 4-digit user pass
code. After power is applied to the system, but before the spreader
is enabled, simultaneously pressing the blast (auger rate knob),
liquid rate knob, and pause (spinner rate knob) buttons allows
entry of the pass code. The buttons is held for >2 sec. After
the sequence is performed, the auger display will read CA, and the
liquid and spinner displays will read from left to right a 4-digit
value of 0000. Rotating the liquid rate knob clockwise will
increase the 2 most significant digits value in 1-step increments.
Rotating the liquid rate knob counterclockwise will decrease the
value in 1-step increments. Rotating the spinner rate knob
clockwise will increase the 2 least significant digits value in
1-step increments. Rotating the spinner rate knob counterclockwise
will decrease the value in 1-step increments. Upon reaching the
desired pass code, the user will press and release the spinner rate
knob. If the pass code is incorrect, the auger, liquid, and spinner
displays will go dark and the user should repeat the startup
sequence. A factory master pass code of 5555 will allow entry into
the calibration menu.
[0139] Once in the calibration menu of Table 1, items listed below
may be accessed for calibration. Scrolling through the menu items
is accomplished by turning the auger rate knob. Unless otherwise
noted, turning the spinner rate knob allows selection of the value,
and pressing the spinner rate knob updates the value in memory.
TABLE-US-00001 TABLE 1 AUGER LIQUID SPINNER MENU ITEM DISPLAY
DISPLAY DISPLAY Auger Min Trim AU LO VALUE (0-99) Auger Max Trim AU
HI VALUE (0-99) Spinner Min Trim SP LO VALUE (0-99) Spinner Max
Trim SP HI VALUE (0-99) Liquid Min Trim LI LO VALUE (0-99) Liquid
Max Trim LI HI VALUE (0-99) Groundspeed input GS VALUE (0-2)
Selection Blast Time Out Seconds BL TO VALUE (0-30) Blast Level BL
HI VALUE (0-99) Speedometer GS CA VALUE (10-40)
calibration/verification Auger rate calibration AU RT VALUE (0-10)
Liquid PWM Frequency LF VALUE (50-200) Hz - (50-200) Flow Control
Valve Drive FC DR VALUE (0-99) Dump Hoist Valve Drive DH DR VALUE
(0-99) Flow Control Min Trim PF LO VALUE (0-99) Flow Control Max
Trim PF HI VALUE (0-99) Hoist up Min Trim HU LO VALUE (0-99) Hoist
up Max Trim HU HI VALUE (0-99) Hoist down Min Trim HD LO VALUE
(0-99) Hoist down Max Trim HD HI VALUE (0-99) Joystick neutral Dead
band JY DB VALUE (0-5) Product 2 material ratio PR 02 VALUE
(0.5-1.5) Product 3 material ratio PR 03 VALUE (0.5-1.5) Pass code
change PC VALUE (0-9999) Auto Mode Takeoff AM TO VALUE (0-9) Exit
menu EX IT
[0140] With regards to speedometer calibration, Upon entering this
menu item, the user will turn the spinner rate knob to set the
desired MPH value for calibration or verification. If the user
desires to re-calibrate, they should accelerate the vehicle to the
selected MPH value. While maintaining the selected vehicle speed
pressing the spinner rate knob will complete calibration. If the
present speed of the vehicle reaches the displayed MPH value (based
upon the present calibration value), the MPH value will flash.
[0141] With regards to auger rate calibration, this calibration
includes 3 operations, start cal, stop cal, and enter dispensed
material weight. Start Cal--Upon entering this menu item, the user
will turn the spinner rate knob to set the reference value for the
auger speed, and press the spinner rate button. The auger output
will provide output current corresponding to the reference value.
Stop Cal--The user will press the spinner rate button again to stop
the auger output. The display will show "LB VALUE (0000-5000)."
Enter weight--Next the auger rate display will read LB, with the
liquid and spinner displays reading 00 and 00. The user will turn
the liquid rate knob clockwise to increase and counter clockwise to
decrease (1 step increments), until the liquid display digits match
the 2 most significant digits of the dispensed material weight in
pounds. The user will turn the spinner rate knob clockwise to
increase and counter clockwise to decrease (1 step increments),
until the spinner display digits match the least significant digits
of the dispensed material weight in pounds. The user will again
press the spinner rate knob to complete calibration. The liquid
rate knob controls 2 MSD, the spinner rate knob controls 2 LSD.
[0142] With regards to the Product2 material ratio,--This is a
ratio of the dispense rate for a product as compared to the
dispense rate of the product used during the auger calibration.
With regards to the Product3 ratio,--This is a ratio of the
dispense rate for a given product as compared to the dispense rate
of the product used during the auger calibration.
[0143] In some embodiments of the present invention the master
power distribution unit and electrical interface unit 50 pertain
to:
[0144] The master power distribution unit 50 will monitor inputs,
provide outputs, send commands to the control panel, accept
commands from the control panel, and control any slave power
distribution units. Output functionality, where applicable will
perform according to the hydraulic function chart on the last page.
The following items describe the input and output requirements for
the MPDU.
[0145] Ground Speed Input: Input voltage range will be 1 VPP to 100
VPP sinusoidal or square wave input. Configurable as DC coupled
sinking input, DC coupled sourcing input, and AC coupled input as
defined in the calibration menu.
[0146] Serial Input Port: Pins allocated on one side of the 24 pin
Deutsch connector will allow for serial programming of the MPDU in
the field.
[0147] Serial Output port: Pins allocated on one side of the 24-pin
Deutsch connector will provide serial communications between the
master and any slave devices.
[0148] Unloader Output: Provides fixed unregulated voltage source
of up to 3 ampere at the unloader output pin. Refer to attached
hydraulic function chart for output activation.
[0149] Spinner Output: Provides pwm regulated current source of up
to 3 ampere at the spinner valve output pin. The current value is
determined by the spinner rate setting at the front panel. The pwm
output frequency is fixed at 100 Hz.
[0150] Auger Output: Provides pwm regulated current source of up to
3 ampere at the auger output pin. The current value is determined
by the auger rate setting at the front panel. The pwm output
frequency is fixed at 100 Hz.
[0151] Plow Flow Control Output: Provides pwm regulated current
source of up to 3 ampere at the plow flow control output pin. The
current value is determined by the joystick deflection angle or the
flow control valve drive value as defined in the calibration menu.
The pwm output frequency is fixed at 100 Hz.
[0152] Liquid Motor Control Output: Provides pwm regulated current
source of up to 8 ampere at the liquid motor output pins (2
required). The current value is determined by the liquid, and auger
rate settings at the front panel. The pwm output frequency is
determined by the liquid pwm frequency as defined in the
calibration menu.
[0153] Slave Power Distribution Unit: The slave power distribution
unit will receive commands from the master, and provide outputs to
additional hydraulic pieces. The harness connection will determine
the module's functionality as either a plow output module or
scraper output module. Output functionality, where applicable will
perform according to the hydraulic function chart on the last page.
The following items describe the input and output requirements for
the SPDU.
[0154] Hoist Up Output/No Function: Slave module connected to plow
harness provides pwm regulated current source of up to 3 ampere at
the hoist up output pin. The current value is determined by the
dump mode joystick deflection angle or the dump hoist valve drive
value as defined in the calibration menu. The pwm output frequency
is fixed at 100 Hz. Slave module connected to scraper harness
provides no function for this output.
[0155] Hoist Down Output/No Function: Slave module connected to
plow harness provides pwm regulated current source of up to 3
ampere at the hoist down output pin. The current value is
determined by the dump mode joystick deflection angle or the dump
hoist valve drive value as defined in the calibration menu. The pwm
output frequency is fixed at 100 Hz. Slave module connected to
scraper harness provides no function for this output.
[0156] Plow Down Output/Scraper Down Output: Slave module connected
to plow harness provides fixed unregulated voltage source of up to
3 ampere at the plow down/scraper down output pin. Slave module
connected to scraper harness provides fixed unregulated voltage
source of up to 3 ampere at the plow down/scraper down output
pin.
[0157] Plow Left Output/Scraper Left Output: Slave module connected
to plow harness provides fixed unregulated voltage source of up to
3 ampere at the plow down or scraper down output pin. Slave module
connected to scraper harness provides fixed unregulated voltage
source of up to 3 ampere at the plow down/scraper down output
pin.
[0158] Plow Right Output/Scraper Right Output: Slave module
connected to plow harness provides fixed unregulated voltage source
of up to 3 ampere at the plow down or scraper down output pin.
Slave module connected to scraper harness provides fixed
unregulated voltage source of up to 3 ampere at the plow
down/scraper down output pin.
[0159] Plow Up Output/Scraper Up Output: Slave module connected to
plow harness provides fixed unregulated voltage source of up to 3
ampere at the plow down or scraper down output pin. Slave module
connected to scraper harness provides fixed unregulated voltage
source of up to 3 ampere at the plow down/scraper down output
pin.
[0160] Joystick or keypad pushbutton inputs will be mutually
exclusive. If an attempt is made to activate more than one
pushbutton on the joystick, the relevant backlight of the function
mode selected will flash red to dark, and an audible beep will
sound. No associated output will activate. Any involved output that
was active will be turned off. If an attempt is made to activate
more than one input on the keypad, the relevant keys selected will
flash red to dark, and an audible beep will sound. No associated
output will activate. Any involved output that was active will be
turned off.
[0161] The product ratio value menu items will be used to adjust
output current to the auger when the dispense material is changed.
A ratio of 1:1 will apply for the material that is dispensed during
calibration.
[0162] The auto mode takeoff is defined as a timer that controls
the duration the auger will be set to blast when groundspeed is
initially detected. This value is a calibration menu item and will
range from 0-10 seconds.
[0163] Re-programming of the control panel will be accomplished
using a harness connected between a PC and the control panel
joystick input. Re-programming of the master and slave units will
be accomplished using a DB9 to 12 pin Deustch harness connected
between a PC and one of the 12 pin Deustch connectors at each
module. The desired method is to update all modules through the
control panel joystick input using PLC communications.
[0164] The pwm frequency of all pulse width modulated outputs will
be fixed at 100 Hz, except for the liquid output. The liquid pwm
output will be adjustable from 50 Hz to 200 Hz in 50 Hz increments
through a menu item.
[0165] If the maximum specified current for an output is exceeded,
the output will be turned off along with any associated output, and
any relevant backlight at the display will flash with audible beep
indicating a failure.
[0166] In some embodiments of the present invention the vehicle 20
hydraulic system pertains to:
[0167] The functions include: Front Plow 22--Single or Double
acting raise/lower; Front Plow--Double acting angle; Dump
Hoist--Single or Double acting; Auger/conveyor--Proportional Flow
Control; Spinner--Proportional Flow Control; Pre-Wet--Variable
Electric Motor; Valve Drive Characteristics; Valves 1-9: 12VDC@1800
mA/Switched control; Valves 10&11: 12 VDC@2750 mA/Proportional
control/100 Hz PWM; (Current compensated outputs are preferred);
Motor: 12VDC@8000 mA/Proportional control/50 Hz PWM.
[0168] The system 20 functions also include: Proportional
Valve/Motor Trims Provision for trimming the minimum and maximum
drive to the Auger, Spinner and Pre-Wet Motor drives; and
Groundspeed Control: Provision for operation of the Auger valve
drive in proportion to the vehicle speed. This is to be an
open-loop servo design. The endpoints of the operating curve should
be defined by the minimum and maximum trim settings for the auger
drive. The slope of the curve should be controlled by the operation
of the increase or decrease of the auger input control. The curve
will define the relationship of .DELTA.% Valve Drive/.DELTA.MPH.
The net effect of changing the slope will be to move the maximum
valve trim endpoint from an occurrence at 45 MPH (maximum speed) to
a lower MPH value.
[0169] In one embodiment, the system includes valves that operate
generally as follows:
[0170] Circuit Design: The design includes load-sense communication
from all work valves.
[0171] Construction Style: The valve design are preferably solenoid
operated cartridge style with a common manifold. The cartridge
solenoids are preferably rated IP69.
[0172] Flow Priority: There is preferably a flow priority to insure
operation of the cylinder functions whenever the spreader is
operating and pump flow is critically low.
[0173] Proportional Cylinder Control: All cylinders have
proportional flow control on the power sequence to afford cylinder
speed control.
[0174] Pressure Relief Valves: Independent and stem adjustable
pressure protection are preferably included for the manifold inlet,
the spreader, the downside of all double acting cylinders and, plow
angle cylinders.
[0175] Plow Lift Valves: The valves are preferably capable of
four-way control and have a flow capacity sufficient for the flow
rate requirements of the specific actuator. The raise side of the
circuit are preferably rated for zero leakage.
[0176] Plow Angle Valves: The valves are preferably capable of
four-way control and have a flow capacity sufficient for the flow
rate requirements of the specific actuator. Load-locking check
valves or "motor-spool" design are preferably included as to
support the angling mechanism used.
[0177] Dump Hoist Valves: The valves are preferably capable of
four-way control and have a flow capacity sufficient for the flow
rate requirements of the specific actuator. Counter-balance control
valves are preferably included.
[0178] Spreader Valves: The proportional flow control valves for
the Auger/Conveyor and Spinner motors have flow capacities of 15/7
gpm respectively. These valves are preferably pressure compensated
and parallel in their circuit architecture.
[0179] One embodiment of the present invention pertains to an
apparatus for controlling a snowplow of a vehicle, comprising: a
hydraulically actuatable snowplow mounted to the vehicle; a
hydraulic actuator for moving said snowplow; means for providing
controlled hydraulic fluid which receives an actuation signal (such
as a current signal) and provides hydraulic fluid to said actuator
in response thereto; a computer controller which receives a command
signal and produces said actuation signal in response thereto; a
joystick movable in a direction over a range of positions and
providing a first data signal which is proportional to the position
of said joystick; and a keypad having first and second manual
switches, said first switch providing a predetermined second data
signal when switched, said second switch providing a predetermined
third data signal when switched; wherein said first data signal,
said second data signal, and said third data signal correspond to a
desired rate of movement of said snowplow, and one of said first
data signal, said second data signal, or said third data signal
correspond to said command signal.
[0180] Yet another embodiment of the present invention pertains to
the apparatus described herein which further comprises a
hydraulically actuatable dump body mounted to the vehicle and
movable over a second range of positions; a second hydraulic
actuator for moving the dump body over the second range at a rate
of movement; the electrohydraulic interface unit receiving a dump
signal and providing hydraulic fluid to the second actuation in
response thereto; and a selection switch providing a selection
signal to the electrical interface unit, the electrical interface
unit using the state of the selection switch to determine if the
first data signal corresponds to movement of the dump body or
movement of the snowplow.
[0181] Yet another embodiment of the present invention pertains to
any of the apparatus of methods described herein wherein the
electrohydraulic interface unit includes at least one proportional
solenoid and at least one spool valve, the solenoid applying a
force to the valve which is proportional to the actuation
signal.
[0182] Yet another embodiment of the present invention pertains to
any of the apparatus of methods described herein wherein the
vehicle includes a DC electrical system, the actuation signal is at
a frequency, and the electrical interface unit places the actuation
signal on the DC electrical system.
[0183] Yet another embodiment of the present invention pertains to
any of the apparatus of methods described herein which further
includes a third switch adjustable by the vehicle operator and
providing an output variable between high and low limits, wherein
the output of the third switch establishes the second data
signal.
[0184] Another embodiment of the present invention pertains to an
apparatus for controlling the snow removal functions of a vehicle,
comprising: a vehicle including a hydraulically actuatable first
tool and a second actuatable tool; an electrohydraulic interface
unit which receives an actuation signal and provides hydraulic
fluid to said snowplow or said tool in response thereto; a
distributed electronic control system which includes a main
controller which receives a command signal and transmits a coded
command signal over a plc network, a remote controls that received
the coded command signal and produces said actuation signal in
response thereto, said main controller receiving an identification
signal and responsive to select one of said first tool or said
second tool for actuation in response thereto; and a joystick
movable in each of two directions over a range of positions and
providing said command signal which is proportional to the position
of said joystick, said joystick including a first switch and a
second switch; wherein the states of said first switch and second
switch provides said identification signal
[0185] Yet another embodiment of the present invention pertains to
any of the apparatus or methods described herein which further
comprises a hydraulically actuatable dump body and a third switch,
the electrohydraulic interface unit providing hydraulic fluid to
dump body, the electrical interface unit selecting one of the
snowplow, tool, or dump body for actuation, and wherein the states
of the first switch, second switch, and third switch provides the
identification signal.
[0186] Yet another embodiment of the present invention pertains to
any of the apparatus or methods described herein wherein the
joystick includes a deadman switch providing a signal to the
electrical interface unit corresponding to the presence of a user
of the vehicle, the electrical interface unit providing the
actuation signal only if the user is present.
[0187] Yet another embodiment of the present invention pertains to
any of the apparatus of methods described herein wherein the
joystick includes dual redundant sensors for providing the command
signal.
[0188] Yet another embodiment of the present invention pertains to
any of the apparatus or methods described herein wherein the
joystick is centerable in each of the two directions and the
electrical interface unit is programmable to apply a deadband
region to each direction.
[0189] Another embodiment of the present invention pertains to a
method for controlling the snowplow of a truck, comprising:
providing a truck having an actuatable snowplow actuatable in each
of two directions at a variable rate of movement and a two axis
controller, wherein the controller is moveable in each axis over a
range of positions, the snowplow is actuatable in each direction
over a range of rates of movement, and the range of positions
corresponds to the range of rates; moving the snowplow in one
direction at a predetermined rate in response to movement of the
controller in one axis to a predetermined position; and moving the
snowplow in the other direction at a predetermined rate in response
to movement of the controller in the other axis to a predetermined
position.
[0190] Another embodiment of the present invention pertains to a
system for electronically logging the snow and ice removal
functions of a vehicle, comprising: a vehicle having an electrical
power system and including a snowplow hydraulically actuatable to a
plurality of positions and a system for distributing a granular
product on a roadway within a range of distribution rates; a first
sensor providing a first signal corresponding to the position of
the snowplow, a second sensor providing a second signal
corresponding to the distribution rate of the product, a third
sensor providing a third signal corresponding to the position of
the vehicle, and a clock providing a time signal; and electronic
data capturing and computational module that receives the first
signal, second signal, third signal, and time signal, the first
signal and second signal being transmitted from the corresponding
said sensor to said module by communication over the power system,
said module using the second signal, third signal, and time signal
to compute a product output rate in terms of weight of product
distributed per unit distance.
[0191] Yet another embodiment of the present invention pertains to
any of the apparatus or methods described herein which further
comprises an automatic vehicle locating system, wherein the
computed data is provided to the AVL system.
[0192] While the inventions have been illustrated and described in
detail in the drawings and foregoing description, the same is to be
considered as illustrative and not restrictive in character, it
being understood that only the preferred embodiment has been shown
and described and that all changes and modifications that come
within the spirit of the invention are desired to be protected.
* * * * *