U.S. patent application number 14/606827 was filed with the patent office on 2015-09-03 for system and method of applying material to a surface.
This patent application is currently assigned to Weiler, Inc.. The applicant listed for this patent is William Hood, Patrick Weiler. Invention is credited to William Hood, Patrick Weiler.
Application Number | 20150247294 14/606827 |
Document ID | / |
Family ID | 54006505 |
Filed Date | 2015-09-03 |
United States Patent
Application |
20150247294 |
Kind Code |
A1 |
Weiler; Patrick ; et
al. |
September 3, 2015 |
System and Method of Applying Material to a Surface
Abstract
In accordance with example embodiments, a system may include a
first feeder configured to transport asphalt, a second feeder
configured to receive the asphalt from the first feeder, and a
controller configured to control a speed of the first feeder and
the second feeder in response to an input from an operator.
Inventors: |
Weiler; Patrick; (Pella,
IA) ; Hood; William; (Reasnor, IA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Weiler; Patrick
Hood; William |
Pella
Reasnor |
IA
IA |
US
US |
|
|
Assignee: |
Weiler, Inc.
Knoxville
IA
|
Family ID: |
54006505 |
Appl. No.: |
14/606827 |
Filed: |
January 27, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61947153 |
Mar 3, 2014 |
|
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Current U.S.
Class: |
404/84.05 |
Current CPC
Class: |
E01C 19/48 20130101;
E01C 2301/04 20130101 |
International
Class: |
E01C 19/16 20060101
E01C019/16; E01C 19/45 20060101 E01C019/45; E01C 19/02 20060101
E01C019/02; E01C 7/00 20060101 E01C007/00; E01C 19/00 20060101
E01C019/00 |
Claims
1. A system comprising: a first feeder configured to transport
asphalt; a second feeder configured to receive the asphalt from the
first feeder; and a controller configured to control a speed of the
first feeder and the second feeder in response to at least one of
an input from an operator and a sensor.
2. The system of claim 1, wherein the first feeder includes a first
motor and the second feeder includes a second motor and the
controller is configured to control the first and second
motors.
3. The system of claim 2, wherein the first motor is a hydraulic
motor and the second motor is a hydraulic motor.
4. The system of claim 3, wherein the first motor is controlled by
first hydrostatic pump and the second motor is controlled by a
second hydrostatic pump and the controller controls the first and
second hydrostatic pumps to control the first and second hydraulic
motors.
5. The system of claim 1, wherein the controller is configured to
substantially simultaneously increase and decrease speeds of the
first and second feeders based on the input from the operator.
6. The system of claim 1, further comprising: a third feeder
configured to receive the asphalt from the second feeder, wherein
the controller is further configured to control a speed of the
third feeder in response to the input from the operator.
7. The system of claim 1, further comprising: a third feeder
configured to provide the asphalt to the second feeder, wherein the
third feeder is controlled independently of the first and second
feeders.
8. The system of claim 1, further comprising: a first load sensor
configured to measure a first load associated with the first
feeder; and a second load sensor configured to measure a second
load associated with the second feeder, wherein the controller is
further configured to control a speed of the first and second
feeders based on at least one of the first and second loads.
9. The system of claim 8, wherein the first feeder includes a first
motor and the second feeder includes a second motor and the first
load is a first pressure and the second load is a second
pressure.
10. The system of claim 9, wherein the first and second motors are
hydraulic motors.
11. A method comprising: moving asphalt with a first feeder; moving
the asphalt with a second feeder, the second feeder receiving the
asphalt from the first feeder; and controlling speeds of the first
feeder and the second feeder by inputting an input to a
controller.
12. The method of claim 11, wherein the first feeder includes a
first motor and the second feeder includes a second motor and
controlling speeds of the first and second feeders includes
controlling speeds of the first and second motors.
13. The method of claim 12, wherein the first motor is a hydraulic
motor and the second motor is a hydraulic motor.
14. The method of claim 13, wherein the first motor is controlled
by first hydrostatic pump and the second motor is controlled by a
second hydrostatic pump and controlling speeds of the first and
second motors includes controlling speeds of the first and second
hydrostatic pumps.
15. The method of claim 11, wherein controlling speeds of the first
and second feeders includes one of substantially simultaneously
increasing and decreasing speeds of the first and second
feeders.
16. The method of claim 11, further comprising: moving the asphalt
with a third feeder, wherein the controller is further configured
to control a speed of the third feeder in response to the input
from the operator.
17. The system of claim 11, further comprising: moving the asphalt
via a third feeder to the second feeder, wherein the third feeder
is controlled independently of the first and second feeders.
18. The method of claim 11, further comprising: controlling speeds
of the first and second feeders based on at least one of a first
load sensed by a sensor configured to measure a load associated
with the first feeder and a second load sensor configured to
measure a load associated with the second feeder.
19. The method of claim 11, wherein the first feeder includes a
first motor and the second feeder includes a second motor and the
first load is a first pressure and the second load is a second
pressure.
20. The system of claim 19, wherein the first and second motors are
hydraulic motors.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent
Application No. 61/947,153 which was filed with the United States
Patent and Trademark Office on Mar. 3, 2014, the entire contents of
which are herein incorporated by reference.
BACKGROUND
[0002] 1. Field
[0003] Example embodiments relate to systems and methods of
applying a material, for example, asphalt, to a surface.
[0004] 2. Description of the Related Art
[0005] FIG. 1A is a view of a system 5 used for applying asphalt to
a road. As shown in FIG. 1A, the system 5 includes a dump truck 10,
a material transfer vehicle 50, and a paver 90. In the conventional
art, the material transfer vehicle 50 includes a hopper 55, a first
feeder 60, a second feeder 65, and a third feeder 70. The hopper 55
is configured to receive asphalt from the dump truck 10 and the
first feeder 60 is configured to move the asphalt to the second
feeder 65. The second feeder 65 includes an auger system to mix the
asphalt and feed the asphalt to the third feeder 70 which, in turn,
is configured to move the asphalt to the paver 90.
[0006] FIG. 1B is a partial schematic view of the material transfer
vehicle 50. As shown in FIG. 1B, the material transfer vehicle 50
includes a first electronically controlled hydrostatic pump
configured to drive a first hydraulic drive motor which in turn is
configured to drive the first feeder 60, a second electronically
controlled hydrostatic pump configured to drive a second hydraulic
drive motor which in turn is configured to drive the second feeder
65, and a third electronically controlled hydrostatic pump
configured to drive a third hydraulic drive motor which in turn is
configured to drive the third feeder 70. In the conventional art
the first feeder 60 may be controlled by a user input whereas the
second and third feeders 65 and 70 receive a fixed signal so that
they operate at a relatively high speed.
[0007] In the system 5 of FIG. 1A the first feeder 60 includes a
chain 72 driven by a sprocket which is driven by a hydraulic motor.
FIG. 2, for example, is a partial view of the chain 72. The chain
72 resembles a belt with paddles and/or slats 75 used to move the
asphalt 80 along the first feeder 60. Similarly, the third feeder
70 includes a chain which also resembles a belt with paddles and/or
slats.
[0008] FIG. 3A is a view of another system 100 used for applying
asphalt to a road. As shown in FIG. 3A, the system 100 includes a
dump truck 110, a material transfer vehicle 150, and a paver 190.
In this conventional system 100 the material transfer vehicle 150
includes a first hopper 155, a first feeder 160, a second hopper
157, a second feeder 165, and a third feeder 170. The first hopper
155 is configured to receive asphalt from the dump truck 110 and
the first feeder 160 is configured to move the asphalt to the
second hopper 157 where it is transferred, via the second feeder
165, to the third feeder 170. The third feeder 170, in turn, moves
the asphalt to the paver 190. In this system 100, the first,
second, and third feeders 160, 165, and 170 include chains driven
by hydraulic motors. The chains, for example, resemble belts with
paddles and/or slats as was previously described.
[0009] FIG. 3B is a partial schematic view of the material transfer
vehicle 150. As shown in FIG. 3B, the material transfer vehicle 150
includes a first electronically controlled hydrostatic pump
configured to drive a first hydraulic drive motor which in turn is
configured to drive the first feeder 160, a second electronically
controlled hydrostatic pump configured to drive a second hydraulic
drive motor which in turn is configured to drive the second feeder
165, and a third electronically controlled hydrostatic pump
configured to drive a third hydraulic drive motor which in turn is
configured to drive the third feeder 170. In the conventional the
first and second feeders 160 and 165 are controlled by user inputs
and the third feeder 170 is configured to receive a fixed signal
which causes it to operate at a relatively high speed.
[0010] In each of the above described systems 5 and 100, hydraulic
motors are used to control the operations of the first feeders 60
and 160, the second feeders 65 and 165, and the third feeders 70
and 170. In general, the first, second, and third feeders 60 and
160, 65 and 165, and 70 and 170 are independently controlled. In
normal operation, the second feeder 65 and the third feeders 70 and
170 are set to deliver asphalt at a relatively high rate regardless
of the setting of the first feeders 60 and 160 or the second feeder
165. This manner of controlling the systems 5 and 100 prevents
asphalt delivered from the first feeders 60 and 160 to the second
feeders 65 and 165 (and then to the third feeders 70 and 170) from
over-accumulating in the material transfer vehicle.
SUMMARY
[0011] The inventor has noted that while conventional paving
systems do an adequate job of applying asphalt to the ground, the
conventional systems suffer several drawbacks. First, because
conventional systems generally operate certain feeders to deliver
asphalt at a relatively high rate, the wear on these feeders is
relatively high compared to the wear of feeders which may be
operated at a lower rate. Second, because some feeders are
generally set to deliver asphalt at a fairly high rate regardless
of material volume, the asphalt moved by these feeders may cause
the asphalt to unnecessarily segregate. Third, the inventor notes
conventional transfer vehicles lack indicators indicating the level
of asphalt that is present in the material transfer vehicles. As a
consequence, the only way to determine a level of asphalt in a
material transfer vehicle is to manually inspect the material
transfer vehicle storage hopper from above. In view of the above
problems, the inventor has set out to improve conventional systems
and/or methods of applying asphalt to a surface. As a result, the
inventor has developed a novel and nonobvious system and method of
applying asphalt to surfaces. The invention, however, is not
limited thereto, as the inventive concepts recited herein may be
applied in other industries and technologies where materials are
applied to surfaces. For example, the material may be, but is not
limited to, concrete, sand, gravel, or some other material.
[0012] In accordance with example embodiments, a system may include
a first feeder configured to transport asphalt, a second feeder
configured to receive the asphalt from the first feeder, and a
controller configured to control a speed of the first feeder and
the second feeder in response to a single input from an
operator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Example embodiments are described in detail below with
reference to the attached drawing figures, wherein:
[0014] FIGS. 1A and 1B are views of a system in accordance with the
conventional art;
[0015] FIG. 2 is a partial view of a feeder in accordance with the
conventional art;
[0016] FIGS. 3A and 3B are views of another system in accordance
with the conventional art;
[0017] FIG. 4 is a view of a system in accordance with example
embodiments;
[0018] FIG. 5 is a view of a system in accordance with example
embodiments;
[0019] FIG. 6A is a view of a system in accordance with example
embodiments;
[0020] FIG. 6B is a view of a system in accordance with example
embodiments;
[0021] FIG. 6C is a view of a system in accordance with example
embodiments;
[0022] FIG. 6D is a view of a system in accordance with example
embodiments;
[0023] FIG. 6E is a view of a system in accordance with example
embodiments;
[0024] FIG. 7 is a view of a system in accordance with example
embodiments;
[0025] FIG. 8 is a view of a system in accordance with example
embodiments;
[0026] FIG. 9 is a view of a system in accordance with example
embodiments;
[0027] FIG. 10 is a view of a system in accordance with example
embodiments;
[0028] FIG. 11 is a partial view of a hopper with a level sensor
and a proximity sensor in accordance with example embodiments;
[0029] FIG. 12 is a partial view of a hopper with a material inside
in accordance with example embodiments; and
[0030] FIG. 13 is a partial view of a hopper with a material inside
in accordance with example embodiments.
DETAILED DESCRIPTION
[0031] Example embodiments will now be described more fully with
reference to the accompanying drawings, in which example
embodiments of the invention are shown. The invention may, however,
be embodied in different forms and should not be construed as
limited to the embodiments set forth herein. Rather, these
embodiments are provided so that this disclosure will be thorough
and complete, and will fully convey the scope of the invention to
those skilled in the art. In the drawings, the sizes of components
may be exaggerated for clarity.
[0032] It will be understood that when an element or layer is
referred to as being "on," "connected to," or "coupled to" another
element or layer, it can be directly on, connected to, or coupled
to the other element or layer or intervening elements or layers
that may be present. In contrast, when an element is referred to as
being "directly on," "directly connected to," or "directly coupled
to" another element or layer, there are no intervening elements or
layers present. As used herein, the term "and/or" includes any and
all combinations of one or more of the associated listed items.
[0033] It will be understood that, although the terms first,
second, etc. may be used herein to describe various elements,
components, regions, layers, and/or sections, these elements,
components, regions, layers, and/or sections should not be limited
by these terms. These terms are only used to distinguish one
element, component, region, layer, and/or section from another
elements, component, region, layer, and/or section. Thus, a first
element component region, layer or section discussed below could be
termed a second element, component, region, layer, or section
without departing from the teachings of example embodiments.
[0034] Spatially relative terms, such as "beneath," "below,"
"lower," "above," "upper," and the like, may be used herein for
ease of description to describe one element or feature's
relationship to another element(s) or feature(s) as illustrated in
the figures. It will be understood that the spatially relative
terms are intended to encompass different orientations of the
structure in use or operation in addition to the orientation
depicted in the figures. For example, if the structure in the
figures is turned over, elements described as "below" or "beneath"
other elements or features would then be oriented "above" the other
elements or features. Thus, the exemplary term "below" can
encompass both an orientation of above and below. The structure may
be otherwise oriented (rotated 90 degrees or at other orientations)
and the spatially relative descriptors used herein interpreted
accordingly.
[0035] Embodiments described herein will refer to plan views and/or
cross-sectional views by way of ideal schematic views. Accordingly,
the views may be modified depending on manufacturing technologies
and/or tolerances. Therefore, example embodiments are not limited
to those shown in the views, but include modifications in
configurations formed on the basis of manufacturing process.
Therefore, regions exemplified in the figures have schematic
properties and shapes of regions shown in the figures exemplify
specific shapes or regions of elements, and do not limit example
embodiments.
[0036] The subject matter of example embodiments, as disclosed
herein, is described with specificity to meet statutory
requirements. However, the description itself is not intended to
limit the scope of this patent. Rather, the inventors have
contemplated that the claimed subject matter might also be embodied
in other ways, to include different features or combinations of
features similar to the ones described in this document, in
conjunction with other technologies. Generally, example embodiments
relate to systems and methods of applying a material, for example,
asphalt, to a surface.
[0037] FIG. 4 is an example of a system having a first feeder 500
and a second feeder 600 in accordance with example embodiments. In
example embodiments the first and second feeders 500 and 600 may be
associated with a paving system and may be configured to move
asphalt. For example, the first and second feeders 500 and 600 may
be associated with a material transfer vehicle.
[0038] In example embodiments the first and second feeders 500 and
600 may include chains that resemble belts with paddles as is well
known in the art. For example, each of the first and second feeder
systems 500 and 600 may include a chain supported by a plurality of
rollers wherein one of the rollers is connected to a sprocket
driven by a motor. In example embodiments, the first feeder 500 may
be powered by a first motor and the second feeder 600 may be
powered by a second motor. In example embodiments, the first and
second motors may be, but are not required to be, hydraulic motors.
For example, the first and second motors may be electric
motors.
[0039] In example embodiments the first feeder 500 may include a
chain of a first size and the second feeder 600 may include a chain
of a second size. Thus, in example embodiments, the chains of the
first and second feeder systems 500 and 600 may move different
amounts of a material if they are operated at the same speed. For
example, if the chain of the first feeder 500 has a width of four
feet and the chain of the second feeder 600 has a width of two feet
and both chains are operated at the same speed, then the first
chain may move twice an amount of material with respect to an
amount of material moved by the second chain over a same time
period. Of course, if the second chain were operated at a speed
which was twice the speed of the first chain then both chains may
move a same amount of material over a given time period.
[0040] In example embodiments the chains of the first and second
feeders 500 and 600 may be controlled simultaneously. As such, the
first and second feeders 500 and 600 may be, but are not required
to be, controlled so that they deliver a same amount of material
over a same time period. For example, in example embodiments, a
first motor configured to operate the first feeder 500 and a second
motor configured to operate the second feeder 600 may be
simultaneously controlled by a controller which may be configured
to receive input from an operator or some other source, for
example, a wireless transmitter or a sensor. In example embodiments
the sensor may be configured to send a signal either directly or
indirectly to the controller. The controller, for example, may be
configured to control the first motor and the second motor based on
the input from the operator or from a signal sent by a sensor, such
that an amount of material moved by the first and second feeders
500 and 600 over a same time period may be the same despite
differing belt sizes by simultaneously reducing and/or minimizing
the speed at which the first and second motors operate.
Furthermore, in example embodiments, each of the first and second
feeders 500 and 600 may be controlled in accordance with single
input provided by the operator or the other source. Though example
embodiments illustrate a concept of controlling first and second
feeders to move a same amount of material over a same time period,
example embodiments are not limited thereto. For example, the
second feeder may be controlled to move more material or less
material than is being provided by the first feeder.
[0041] In example embodiments each of the first and second feeders
500 and 600 may be simultaneously controlled and may be
simultaneously controlled by a single input. Thus, in example
embodiments, if an operator decides to reduce an amount of material
moved by the first feeder 500 the operator may input data to the
controller to reduce a speed of the first motor. In example
embodiments, the controller may further respond by controlling a
speed at which the second motor operates to reduce a speed at which
the second motor operates (thereby reducing a speed of the second
feeder 600). This stands in stark contrast to conventional feeders
of conventional paving systems wherein adjacent feeders are
controlled independently of one another (or are not adjustable) and
adjusting a speed of a first feeder does not change a speed of a
second feeder.
[0042] In example embodiments the controller may be further
configured to receive operating parameters of the first and second
feeders 500 and 600. For example, in example embodiments the first
and second feeders 500 and 600 may include sensors which measure a
parameter such as, but not limited to, pressure, electrical
current, or torque. For example, in the event the first and second
motors of the first and second feeders 500 and 600 are hydraulic
motors, the parameter may be associated with a pressure of a fluid
entering the hydraulic motor. On the other hand, if the first and
second motors are electrical motors then the parameter may be
associated with electrical current flowing through the motors. As
yet another example, the parameter may be torque exerted by the
first and second motors operating the first and second feeders 500
and 600. By measuring the torque (or pressure or current) an
overload on the system may be detected and the system may slow the
first and second feeders 500 and 600 down to minimize wear or it
may control the first and second motors to prevent overloading. For
example, the controller may be a computer having a memory with a
plurality of control parameters stored in a table. In example
embodiments, the control parameters may, for example, be related to
pressure or current or torque. For example, if torque exerted by
the first motor exceeds a first value the controller may be
configured to reduce a speed of the first motor and the second
motor to prevent the first motor from overloading while still
maintaining a consistent material flow through the system. On the
other hand, if the torque is relatively low (for example, if no
material is being moved) then the controller may shut off the first
and second motors thereby conserving fuel and wear.
[0043] As indicated above, the controller of example embodiments
may be configured to change speeds of the first feeder 500 and the
second feeder 600. For example, in one example embodiment, the
first and second feeders 500 and 600 may be controlled to operate
at a first non-zero speed. In this particular nonlimiting example
embodiment, an operator may provide a single input to the
controller which either increases or decreases speeds of the first
and second feeders 500 and 600 to a second nonzero speed. In the
alternative, if the first and second feeders 500 and 600 initially
operate at different nonzero speeds, the controller may (in
response to the single input) change a speed of the first feeder
500 to another nonzero speed and change the speed of the second
feeder 600 to another nonzero speed which may or may not be the
same as the speed of the first feeder 500. This latter embodiment
may be especially applicable in cases where the chains of the first
and second feeders 500 and 600 have a different size. Although the
above description indicates that a single input may be used to
change speeds of the first and second feeders 500 and 600, the
invention is not limited thereto. For example, in example
embodiments the controller may be configured to adjust speeds of
the first and second feeders 500 and 600 based on input from
sensors associated with the first and second feeders 500 and 600 or
input from sensors not directly associated with the first and
second feeders 500 and 600. For example, in this latter embodiment
the second feeder 600 may transport asphalt to a hopper of a paver.
The hopper may include a sensor indicating how much asphalt is
residing therein. In this case, the sensor in the hopper may send a
signal which may be utilized by the controller to control the
speeds of first and second feeders 500 and 600. For example, if the
level of asphalt in the hopper is low the controller may increase
the speeds of the first and second feeders 500 and 600. If the
level of asphalt in the hopper is high the controller may increase
the speeds of the first and second feeders 500 and 600.
[0044] FIG. 6A is a block diagram illustrating an implementation of
the inventive concepts. In particular, FIG. 6A illustrates an
example of a system 2000 configured to apply a material to a
surface. In example embodiments the system 2000 includes a
controller 2100, a plurality of electronically controlled
hydrostatic pumps 2200, a plurality of hydraulic drive motors 2300,
a plurality of feeders 2400, and an input module 2500. In example
embodiments the controller 2100 may be an electronic controller,
for example, a computer configured to control the plurality of
hydrostatic pumps 2200. In example embodiments the system 2000 may
be embodied in a material transfer vehicle which may be configured
to transfer a material, for example, asphalt.
[0045] In example embodiments the plurality of electronically
controlled hydrostatic pumps 2200 is illustrated as being comprised
of a first hydrostatic pump 2200-1, a second hydrostatic pump
2200-2, and a third hydrostatic pump 2200-3. The number of
hydrostatic pumps, however, is not intended to limit the invention.
For example, in example embodiments the plurality of electronically
controlled hydrostatic pumps 2200 may include only two hydrostatic
pumps or more than three hydrostatic pumps. Similarly, plurality of
hydraulic drive motors 2300 is illustrated as being comprised of
three hydraulic motors, however, the plurality of hydraulic drive
motors 2300 may include only two hydraulic drive motors or more
than three hydraulic drive motors. Similar yet, the plurality of
feeders 2400 is illustrated as being comprised of three feeders,
however the plurality of feeders 2400 may include only two feeders
or more than three feeders.
[0046] In example embodiments the input device 2500 may be
configured, but is not required to be configured, to be controlled
by an operator. For example, the input device 2500 may resemble a
switch or a dial. In example embodiments the electronic controller
2100 may be configured to control the plurality of feeders 2400
based on the input from the input device 2500. For example, if an
operator decides to increase the rate at which material is moved by
the first feeder 2400-1 of the plurality of feeders 2400 the
operator may use the input device 2500 to send a signal to the
electronic controller 2100. In response, the electronic controller
2100 would control the first feeder 2400-1 by controlling the first
electronically controlled hydrostatic pump 2200-1 and hydraulic
drive motor 2300-1 to increase the speed of the first feeder
2400-1. Simultaneously (or nearly simultaneously) the electronic
controller 2100 may also control the second and third feeders
2400-2 and 2400-3 to increase their speeds by controlling the
second and third electronically controlled hydrostatic pumps 2200-2
and 2200-3 and the hydraulic motors 2300-2 and 2300-3 to ensure
material is controllably moved through the system 2000. Thus, in
example embodiments, a single input may adjust the speed of
multiple feeders.
[0047] In addition to the input device 2500, the system 2000 may
include various sensors that may be configured to measure various
operational parameters associated with the plurality of hydraulic
drive motors 2300. These parameters may be uploaded to the
electronic controller 2100 so that the electronic controller 2100
may control the plurality of feeders 2400 based on the sensed
parameters. For example, FIG. 6C illustrates the system 2000 which
further includes pressure sensors 2500-1, 2500-2, and 2500-3. In
example embodiments the pressure sensor 2500-1 may, for example,
sense a pressure of fluid between the first electronically
controlled hydrostatic pump 2200-1 and the first hydraulic drive
motor 2300-1, the pressure sensor 2500-2 may, for example, sense a
pressure of fluid between the second electronically controlled
hydrostatic pump 2200-2 and the second hydraulic drive motor
2300-2, and the pressure sensor 2500-3 may, for example, sense a
pressure of fluid between the third electronically controlled
hydrostatic pump 2200-3 and the third hydraulic drive motor 2300-3.
In example embodiments the pressure sensors 2500-1, 2500-2, and
2500-3 may communicate data to the electronic controller 2100
either through wires or wirelessly and the electronic controller
2100 may use this data to control the speeds of the first, second,
and third feeders 2400-1, 2400-2, and 2400-3. For example, if a
pressure sensed by any one of the three sensor 2500-1, 2500-2, and
2500-3 is above or below a first preset or predetermined value the
electronic controller 2100 may simultaneously increase or decrease
the speed of the first, second, and third feeders 2400-1, 2400-2,
and 2400-3.
[0048] FIG. 6B is a block diagram of another system 2000' in
accordance with example embodiments. In example embodiments the
system 2000' shares many features in common with the system 2000 of
FIG. 6A. For example, in example embodiments, the system 2000'
includes a controller 2100', a plurality of electronically
controlled hydrostatic pumps 2200', a plurality of hydraulic drive
motors 2300', a plurality of feeders 2400', and an input module
2500'. In example embodiments the controller 2100' may be an
electronic controller, for example, a computer configured to
control at least some of hydrostatic pumps of the plurality of
hydrostatic pumps 2200'.
[0049] In example embodiments the plurality of electronically
controlled hydrostatic pumps 2200' is illustrated as being
comprised of a first hydrostatic pump 2200-1', a second hydrostatic
pump 2200-2', and a third hydrostatic pump 2200-3'. The number of
hydrostatic pumps, however, is not intended to limit the invention.
For example, in example embodiments the plurality of electronically
controlled hydrostatic pumps 2200' may include only two hydrostatic
pumps or more than three hydrostatic pumps. Similarly, the
plurality of hydraulic drive motors 2300' is illustrated as being
comprised of three hydraulic motors, however, the plurality of
hydraulic drive motors 2300' may include only two hydraulic drive
motors or more than three hydraulic drive motors. Similar yet, the
plurality of feeders 2400' is illustrated as being comprised of
three feeders, however the plurality of feeders 2400' may include
only two feeders or more than three feeders.
[0050] In example embodiments the input device 2500' may be
configured, but is not required to be configured, to be controlled
by an operator. For example, the input device 2500' may resemble a
switch or a dial. In example embodiments the electronic controller
2100' may be configured to control at least some of the feeders of
the plurality of feeders 2400' based on the input from the input
device 2500'. For example, if an operator decides to increase the
rate at which material is moved by the second feeder 2400-2' and
third feeder 2400-3' of the plurality of feeders 2400' the operator
may use the input device 2500' to send a signal to the electronic
controller 2100'. In response, the electronic controller 2100' may
control the second and third feeders 2400-2' and 2400-3' to
increase their speeds by controlling the second and third
electronically controlled hydrostatic pumps 2200-2' and 2200-3' and
the hydraulic motors 2300-2' and 2300-3' to ensure material is
controllably moved through the system 2000'.
[0051] In addition to the input device 2500', the system 2000' may
include various sensors that may be configured to measure various
operational parameters, for example, a fluid pressure associated
with the plurality of hydraulic drive motors 2300'. These
parameters may be uploaded to the electronic controller 2100' so
that the electronic controller 2100' may control at least some of
the feeders of the plurality of feeders 2400' based on the sensed
parameters. For example, FIG. 6D illustrates the system 2000'
further including pressure sensors 2500-2' and 2500-3'. In example
embodiments the pressure sensor 2500-2' may, for example, sense a
pressure of fluid between the second electronically controlled
hydrostatic pump 2200-2' and the second hydraulic drive motor
2300-2', and the pressure sensor 2500-3' may, for example, sense a
pressure of fluid between the third electronically controlled
hydrostatic pump 2200-3' and the third hydraulic drive motor
2300-3'. In example embodiments the pressure sensors 2500-2' and
2500-3' may communicate data to the electronic controller 2100'
either through wires or wirelessly and the electronic controller
2100' may use this data to control the speeds of the second and
third speeders 2400-2' and 2400-3'. For example, if a pressure
sensed by any one of the two sensors 2500-2' and 2500-3' is above
or below a first preset or predetermined value the electronic
controller 2100' may simultaneously increase or decrease the speed
of the second and third feeders 2400-2' and 2400-3'.
[0052] In example embodiments the system 2000' is similar to the
system 2000 in many respects. However, in example embodiments the
controller 2100 is configured to simultaneously control all of the
feeders of the plurality of feeders 2400 whereas the controller
2100' is configured to provide simultaneous control of only a few
of the feeders of the plurality of feeders 2400'. Thus, in the
system 2000', the speed of the first feeder 2400-1 may be
controlled independently from the speeds of the second and third
feeders 2400-2' and 2400-3'. In example embodiments, this may be
accomplished by providing a separate input means 2501' which may be
connected to a controller (not shown) which controls the first
electronically controlled hydrostatic pump 2200-1' and hydraulic
motor 2300-1'. This, however, is not meant to be a limiting feature
of example embodiments. For example, rather than providing a
separate input means 2501' and a separate controller the system
2000' may use the input module 2500' to send a signal to the
controller 2100' which may be configured to operate the second and
third feeders 2400-2' and 2400-3' independently of the first feeder
2400-1'. In the alternative, the separate input means 2501' may
send a signal, either wirelessly or over wires, to the electronic
controller 2100'. In this embodiment the electronic controller
2100' may be further configured to control the first electronically
controlled hydrostatic pump 2200-1'. As such, in the embodiment of
FIG. 6B, two user inputs may control the system 2000'. The first
user input may be provided to the electronic controller 2100' to
control a speed of the first feeder 2400-1' and the second input
may be provided to the electronic controller 2100' to
simultaneously control the second and third feeders 2400-2' and
2400-3'. It is understood in example embodiments that although FIG.
6B illustrates two input means 2500' and 2501' to provide input,
the two input means 2500' and 2501' may be integrated as a single
device configured to send two user inputs to the electronic
controller 2100' and the electronic controller 2100' may be
configured to control the first feeder 2400-1' based on a first
user input and control the feeders 2400-2' and 2400-3'
simultaneously based on a second input.
[0053] FIG. 6E is a block diagram illustrating another
implementation of the inventive concepts. In particular, FIG. 6E
illustrates an example of a system 2000'' configured to apply a
material to a surface. In example embodiments the system 2000''
includes a controller 2100'', a plurality of electronically
controlled hydrostatic pumps 2200'', a plurality of hydraulic drive
motors 2300'', a plurality of feeders 2400'', and an input module
2500''. In example embodiments the controller 2100'' may be an
electronic controller, for example, a computer configured to
control at least some of the plurality of hydrostatic pumps 2200''.
For example, in FIG. 6E the electronic controller 2100'' is
illustrated as being configured to control two of the three
illustrated electronically controlled hydrostatic pumps. In example
embodiments the system 2000'' may be embodied in a material
transfer vehicle which may be configured to transfer a material,
for example, asphalt.
[0054] In example embodiments the plurality of electronically
controlled hydrostatic pumps 2200'' is illustrated as being
comprised of a first hydrostatic pump 2200-1'', a second
hydrostatic pump 2200-2'', and a third hydrostatic pump 2200-3''.
The number of hydrostatic pumps, however, is not intended to limit
the invention. For example, in example embodiments the plurality of
electronically controlled hydrostatic pumps 2200'' may include only
two hydrostatic pumps or more than three hydrostatic pumps.
Similarly, plurality of hydraulic drive motors 2300'' is
illustrated as being comprised of three hydraulic motors, however,
the plurality of hydraulic drive motors 2300'' may include only two
hydraulic drive motors or more than three hydraulic drive motors.
Similar yet, the plurality of feeders 2400'' is illustrated as
being comprised of three feeders (2400-1'', 2400-2'', and
2400-3''), however the plurality of feeders 2400'' may include only
two feeders or more than three feeders.
[0055] In example embodiments the input device 2500'' may be
configured, but is not required to be configured, to be controlled
by an operator. In addition (or in the alternative) the electronic
controller 2100'' may be configured to receive input from a sensor
2600'' which may sense a parameter associated with one of the
elements of the system 2000''. For example, as shown in FIG. 6E,
the sensor 2600'' is shown as being positioned to sense a parameter
associated with the first feeder 2400-1''. For example, the sensor
2600'' may be configured to sense how fast a chain of the first
feeder 2400-1'' is being operated and may send data related to the
speed of the chain back to the electronic controller 2100'' which
may use this data to control the second and/or third feeders
2400-2'' and 2400-3''.
[0056] In example embodiments the sensor 2600'' is shown as being
configured to sense a parameter associated with the first feeder
2400-1'', however, this is not intended to limit example
embodiments. For example, rather than positioning the sensor 2600''
to detect a parameter of the first feeder 2400-1'', the sensor
2600'' may be configured to sense a parameter associated with
another component of the system 2000'', for example, pressure
associated with the first hydraulic drive motor 2300-1''. In this
latter embodiment the controller 2100'' may use this sensed
parameter to control the second and/or third feeders 2400-2 and
2400-3. Examples of the sensor 2600'' may be, but are not required
to be, a flow meters, sonic sensors, and amperage sensing
devices.
[0057] In example embodiments the system 2000'' may further include
a user input 2500'' to provide communication between a user and the
electronic controller 2100''. For example, the input device 2500''
may resemble a switch or a dial. In example embodiments the
electronic controller 2100'' may be configured to control the
plurality of feeders 2400 based on the input from the input device
2500''. For example, if an operator decides to increase the rate at
which material is moved by the second feeder 2400-2'' and the third
feeder 2400-3'' of the plurality of feeders 2400'' the operator may
use the input device 2500'' to send a signal to the electronic
controller 2100''. In response, the electronic controller 2100''
would control the second feeder 2400-2'' and the third feeder
2400-3'' by controlling the second electronically controlled
hydrostatic pump 2200-2'' and the third hydrostatic pump 2200-3''
to increase the speed of the second and third feeders 2400-2'' and
2400-3''.
[0058] In example embodiments, the system 2000'' may further
include a second user input 2501''. Like the first user input
2500'', the second user input 2501'' may be, but is not required to
be, a switch or a dial. In the nonlimiting example of FIG. 6E the
second user input 2501'' may be used to control the first
electronically controlled hydrostatic pump 2200-1'' which thereby
controls the first hydraulic drive motor 2300-1'' and the first
feeder 2400-1''. In example embodiments the electronic controller
2100'' may be configured to control the second and third feeders
2400-1'' and 2400-3'' based on a parameter sensed by the sensor
2600''. For example, if a user controls the first feeder 2400-1''
via the second user input 2501'' the electronic controller 2100''
may control the second and third feeders 2400-1'' and 2400-3''
based on information sensed by the sensor 2600''. In this manner, a
user may directly control a speed of the first feeder 2400-1'' and
indirectly control the speeds of the second and third feeders
2400-2'' and 2400-3'' via the controller 2100'' which receives
input from the sensor 2600''.
[0059] In example embodiments the electronic controllers 2100,
2100', and 2100'' may be further configured to receive a signal and
control the plurality of feeders 2400, 2400', and 2400'' based on
the signal. For example, in example embodiments the systems 2000,
2000', and 2000'' may be embodied in a material transfer vehicle
configured to transport asphalt to a hopper of a paver. In example
embodiments, the hopper of the paver may include a sensor to detect
an amount of asphalt in the hopper. In example embodiments the
sensor may send a signal to the electronic controllers 2100, 2100',
and 2100'' either directly, or indirectly, and the electronic
controllers 2100, 2100', and 2100'' may control the plurality of
feeders 2400, 2400', and 2400'' based on the signal. For example,
if the signal sent by the sensor in the hopper indicated the level
of asphalt therein was too high the electronic controllers 2100,
2100', and 2100'' may slow the speeds of the plurality of feeders
2400, 2400', and 2400''. Conversely, if the signal sent by the
sensor in the hopper indicated the level of asphalt therein was too
low the electronic controllers 2100, 2100', and 2100'' may increase
the speeds of the plurality of feeders 2400, 2400', and 2400''.
[0060] FIG. 7 is a view of a paving system 5000 which implements
the system 2000 of FIG. 6A and or 6C. As shown in FIG. 7, the
paving system 5000 may include a dump truck 5100, a material
transfer vehicle 5200, and a paver 5300. The material transfer
vehicle 5200 may be substantially identical to a material transfer
vehicle marketed under Weiler E1250A which has been available since
2007. In example embodiments, the material transfer vehicle 5200
may include a hopper 5255, the first feeder 2400-1, the second
feeder 2400-2, and the third feeder 2400-3. The hopper 5255 may be
configured to receive asphalt from the dump truck 5100 and the
first feeder 2400-1 may be configured to move the asphalt to the
second feeder 2400-2. The second feeder 2400-2 may include an auger
system to mix the asphalt and feed the asphalt to the third feeder
2400-3 which, in turn, is configured to move the asphalt to the
paver 5300. As such, the system 5000 of example embodiments is
similar to the conventional art illustrated in FIGS. 1A and 1B,
however, unlike the conventional art, the system 5000 further
includes the controller 2100 which may be configured to control the
first electronically controlled hydrostatic pump 2200-1 and the
first hydraulic motor 2300-1 which controls the first feeder
2400-1. Similarly, the controller 2100 may also be configured to
control the second electronically controlled hydrostatic pump
2200-2 and the second hydraulic motor 2300-2 which controls the
second feeder 2400-2. Similar yet, the controller 2100 may also be
configured to control the third electronically controlled
hydrostatic pump 2200-3 and the third hydraulic motor 2300-3 which
controls the third feeder 2400-3. In this particular example, an
operator may use the input device 2500 (which may be a single input
device) to control a speed of the first feeder 2400-1 to increase
or decrease the speed at which the first feeder 2400-1 operates.
When the speed of the first feeder 2400-1 is either increased or
decreased the controller 2100 automatically controls the second and
third feeders 2400-2 and 2400-3 to increase or decrease their
speeds as well. As such, the system 5000 is controlled such that
asphalt (or another material) may move through the system 5000 in a
controlled manner. Furthermore, the system is controlled such that
a single input allows for simultaneous control of three feeders.
Further yet the system 5000 may be configured so that the first
feeder 2400-1, the second feeder 2400-2, and the third feeder
2400-3 are controlled so as to move a same amount of material
despite having different belt sizes and/or different volumetric
potential.
[0061] FIG. 8 is a view of another paving system 6000 which
implements the system 2000' of FIG. 6B and/or 6D. As shown in FIG.
8, the paving system 6000 may include a dump truck 6100, a material
transfer vehicle 6200, and a paver 6300. The material transfer
vehicle 6200 may be substantially identical to a material transfer
vehicle marketed under Weiler E2850 which has been available since
2010. In example embodiments, the material transfer vehicle 6200
may include a hopper 6255, the first feeder 2400-1', the second
feeder 2400-2', and the third feeder 2400-3'. The hopper 6255 may
be configured to receive asphalt from the dump truck 6100 and the
first feeder 2400-1' may be configured to move the asphalt to the
second hopper 6257. The second feeder 2400-2' may be configured to
receive the asphalt from the second hopper 6257 and move the
asphalt to the third feeder 2400-3' which, in turn, may be
configured to move the asphalt to the paver 6300. As such, the
system 6000 of example embodiments is similar to the conventional
art illustrated in FIGS. 3A and 3B, however, unlike the
conventional art, the system 6000 further includes the controller
2100' which may be configured to control the second electronically
controlled hydrostatic pump 2200-2' and the second hydraulic motor
2300-2' which controls the second feeder 2400-2'. Similar yet, the
controller 2100' may also be configured to control the third
electronically controlled hydrostatic pump 2200-3' and the third
hydraulic motor 2300-3' which controls the third feeder 2400-3'. In
this particular example, an operator may use the input device 2500'
to simultaneously control a speed of the second and third feeders
2400-2' and 2400-3' using a single input to increase or decrease
their speeds to ensure a consistent flow of material. In this
latter embodiment, the speed of the first feeder 2400-1' may be
adjusted without having to adjust the speeds of the second and
third feeders 2400-2' and 2400-3'. As such, the system 6000 is
controlled such that asphalt (or another material) may move through
the system 6000 in a controlled manner.
[0062] In example embodiments, the controllers 2100 and 2100' may
be computers with software loaded thereon to enable control of
their associated feeders. This software may have algorithms
embedded therein which prevent a user from controlling various
feeder speeds. For example, in some situations, for example, when
the systems 2000 and 2000' are initially activated at a job site,
the feeders 2400 and 2400' may be relatively cold. If the feeders
2400 and 2400' were operated at a slow rate when the feeders 2400
and 2400' are cold the asphalt may cool too quickly and cause some
of the feeders 2400 and 2400' to clog up. In order to prevent this
from happening, the controllers 2100 and 2100' may have algorithms
built therein which cause certain feeders (for example, feeders
2400-2, 2400-3, and 2400-3') to operate at a fairly high speed for
a certain time period, for example, fifteen minutes after start up,
in order to ensure the feeders 2400 and 2400' are sufficiently
warmed for efficient material transfer after which time the feeders
2400 and 2400' may be controlled via user input. In other words,
the system may have set parameters and when the parameters are met,
the system will activate and allow operators to have full control
of the variable speed feeder system.
[0063] In accordance with example embodiments, a material transfer
vehicle may contain two or more independently driven conveyor,
chain, auger, belt, or feeder systems in series and the speeds of
independently driven feeder systems may be adjusted simultaneously
with one or more speed adjustment inputs. This stands in stark
contrast to the conventional art wherein speeds of individual
feeder systems in a series of feeders on a material transfer
vehicle were adjusted independently or are not adjustable. Thus, in
the systems according to example embodiments excess feeder system
wear, excess fuel consumption, and an overall inefficiencies may be
reduced. In example embodiments, speed/feed rate adjustment of
multiple systems with one input may allow a machine to operate more
efficiently without additional operator requirements. In addition,
reducing the feeder chain speeds may allow asphalt to move through
the machine feeder system slower with less material segregation.
This may allow better maintenance of temperature of the material
throughout the machine which in turn may also reduce
segregation.
[0064] In example embodiments, a material transfer vehicle may be
equipped with load (pressure, current, torque) monitoring equipment
on the feeder system and/or the material transfer vehicle may be
further equipped with a controller to control an engine or may vary
the RPM of the independently driven feeders. By monitoring the load
on the feeder system and/or engine it may be possible to increase
or decrease feeder speed automatically in order to prevent machine
stalling and excess fuel consumption. If a particular system on the
machine becomes over-loaded, the controls system may slow down the
feeders automatically in order to decrease load. As soon as the
overloading condition subsides the system may increase the speed of
the feeders automatically to return it to a normal use. This may
increase efficient use of machine power while maximizing the
machines loading capabilities. In example embodiments a speed of at
least one of the feeders may be adjusted by changing the electrical
current to the control solenoid on the variable displacement
hydraulic pump or by decreasing engine speed or a combination there
of.
[0065] FIG. 9 is a view of a material transfer vehicle 9000 in
accordance with example embodiments. In FIG. 9, the material
transfer vehicle 9000 is equipped with a sensor 9100 and a material
level indicator 9200 which indicates a level of the material (for
example, asphalt) that may be in a hopper of the material transfer
vehicle 9000. In example embodiments, the sensor 9100 may be, but
is not required to be, an ultrasonic sensor. However, many other
kinds of sensors may be employed which are well known in the art.
For example, the inventive concepts of this application include a
use of a mechanical level gage to determine a level of material in
the hopper. In example embodiments, the material level indicator
9200 may be coupled to the sensor 9100 such that a level of the
material detected by the sensor 9100 may be displayed by the
material level indicator 9200. In this particular nonlimiting
example, the material level indicator 9200 includes three lights
stacked on top of each other. When the level of the material
detected is low only the bottom most light may be activated. When a
level of asphalt detected indicates the hopper is approximately
half full, the bottom two lights may be activated. When the hopper
which is holding the asphalt is full all three lights may be turned
on.
[0066] In example embodiments, the sensor 9100 may be configured to
wirelessly transmit a signal to the electronic controller 2100. For
example, in example embodiments, if the hopper of the transfer
device 9000 is detected as being full, the controller may be
configured to shut off the first feeder to prevent further asphalt
from being loaded into the material transfer vehicle 9000. Example
embodiments, however, are not limited to systems which include
wireless transmission of data. For example, rather than
transmitting data wirelessly, data may be communicated over a wire
which may be installed on the equipment.
[0067] In addition to the above, example embodiments also allow for
a system that uses the sensed data to determine an amount of weight
of asphalt that is stored in the material transfer vehicle 9000. In
this particular nonlimiting example, the sensor may send data to
the controller 2100 which may be configured to use the sensed data
to determine a weight of the material in the material transfer
vehicle 9000. In example embodiments, the controller 2100 may be
configured to shut down the first feeder in the event a weight
limit associated with the material transfer vehicle 9000 is
exceeded (or nearly exceeded) to prevent the material transfer
vehicle 9000 from being overloaded with asphalt.
[0068] In example embodiments, the sensor 9100 may be used to
determine the amount of asphalt inside of the main asphalt storage
hopper on a material transfer vehicle 9000. The signal from the
sensor 9100 may be converted to an output which is displayed as
visible lights external to the machine. These indicator lights may
act as a gauge that allows the operator and other workers around
the machine to see a full range (empty to full) of material inside
the storage hopper. This may also help prevent a material transfer
vehicle from accepting too much material. For example, Applicant
notes that many conventional sites have weight and/or ground
pressure limitations. Thus, by determining how much asphalt is
contained in a hopper of a material transfer vehicle, the inventive
systems allow for a more accurate determination of vehicle weight,
when loaded, to avoid exceeding the aforementioned limitations.
This may also be accomplished by incorporating various load cells
or sensors in the material transfer vehicle in order to measure how
much material is in the hopper of the material transfer
vehicle.
[0069] Previously, an operator on an operator platform 9300 was the
only individual on the jobsite that would be able to monitor the
amount of material inside the storage hopper. The only way the
operator would know the level of material was to uncover the hopper
and physically look inside. The level indicator lights allow the
storage hopper level to be viewed in any condition (night or day)
by anyone on the jobsite while leaving the hopper fully sealed.
With the hopper sealed the asphalt temperature is maintained and
steam/fumes are kept away from the operator.
[0070] Example embodiments provide several advantages over the
prior art. For example, in example embodiments material height may
be visible to an entire crew and/or other machine operators that
may be on a ground level, heat retention of asphalt may be
conserved, steam/fumes may be retained leading to increased job
efficiency.
[0071] Also, as explained above, by sensing the level of material
inside of the storage hopper, another option would be to convert
the level of material into a weight unit. Weight of the material
transfer vehicle is vital on many jobsites to prevent damage to the
surface that the machine is driving on. Through the use of weight
monitoring and feeder control the maximum weight of material that
is contained inside the storage hopper may be controlled. If a
maximum weight limit is set, a feeder that is filling the storage
hopper when the limit is met may be shut off.
[0072] In addition, the control systems of example embodiments may
greatly improve management and planning. Normally when asphalt is
applied to a road it is done so with a fleet of dump trucks which
bring asphalt to the material transfer vehicles. In example
embodiments, the speed of the feeders of the material transfer
vehicles may be adjusted to better match the rate at which the dump
trucks are bringing asphalt to the material transfer vehicles. For
example, if the rate at which the dump trucks are bringing asphalt
to the material transfer vehicles is relatively low, an operator of
the material transfer vehicles may simultaneously slow down at
least some of the feeders to prevent their wear and tear and
conserve fuel.
[0073] Also, an important aspect of many jobs is a requirement that
the level material in the hopper cannot be below a certain
percentage from full; this is to prevent asphalt segregation.
Through the use of the level/weight monitoring a level minimum may
be set that would not allow material within the hopper to drop
below a set parameter. In addition, if the system is running
without material (load) for a certain amount of time the feeders
may be turned off without operator input to prevent excess wear on
components.
[0074] FIG. 10 is a view of a system 10000 in accordance with
example embodiments. In example embodiments, the system 10000 may
include a first feeder 10160 configured to move a material, for
example, asphalt, to a hopper 10157, and a second feeder configured
to move the asphalt to a third feeder 10170 which may transfer the
asphalt to a paver. In example embodiments, the system 10000 may
resemble the Weiler E2850 material transfer vehicle modified as
described above so that a single input may modify speeds of more
than one feeder. However, the system 10000 may further include
devices to quantify how much material may be present in the hopper
10157. The devices, for example, may include a distance sensor
10100 (for example, an ultrasonic sensor) and an inclination sensor
10200.
[0075] FIG. 11 is a cross section view of the hopper being filled
with the material over time. For example, L1 indicates a material
level in the hopper 10157 at a first time, L2 indicates a material
level in the hopper 10157 at a later time and L3 indicates a
material level in the hopper 10157 at yet a later time. As such,
FIG. 11 illustrates the hopper being filled with a material over a
time period. In FIG. 11 the distance sensor 10100 is arranged to
detect the material. As such, the distance sensor 10100 may provide
data indicating how full the hopper 10157 is. When the distance
sensor 10100 detects that the material is relatively close to the
sensor 10100 this information may infer the hopper 10157 is
relatively full.
[0076] Applicant has discovered that while the distance information
from the distance sensor 10100 may be relatively valuable in and of
itself, that the distance information alone may not be an accurate
predictor as to how full a hopper 10157 is. For example, if the
system 10100 is inclined in a first direction the material filling
the hopper 10157 may not have the substantially symmetric pattern
illustrated in FIG. 11, rather, it might have an asymmetric pattern
as shown in FIG. 12. Furthermore, if the system 10000 were inclined
in a second direction, the material filling the hopper 10157 may
have a different asymmetric pattern as shown in FIG. 13. In fact,
the degree of asymmetry may be dependent on the amount the system
10000 is inclined. Thus, the information from the distance sensor
10100 alone may not provide an accurate picture as to how much
material is in the hopper 10157.
[0077] To compensate for inclination, example embodiments may
additionally include the inclination sensor 10200. The inclination
sensor 10200 may measure not only a front to back inclination of
the system 10000, but a left-to-right inclination as well.
Furthermore, placement of the inclination sensor 10200 may be
variable. For example, in one embodiment, the inclination sensor
10200 may be placed in the environment of the hopper 10157 and next
to the distance sensor 10100. In another embodiment, the
inclination sensor 10200 may be placed out of or away from the
hopper 10157 in a controlled area, such as a frame that may be
associated with the system 10000. Thus, the inclination sensor
10200 may be placed in an area away from the hopper 10157 and thus
not be exposed to heat, debris, and other harmful elements that may
be present in the hopper 10157. When the data from the inclination
sensor 10200 is combined with the data from the distance sensor
10100, the combination of data may present a more accurate picture
as to how full the hopper 10157 is compared to a system which only
includes a distance sensor 10100. Also, although the embodiments
thus far have described only a single distance sensor 10100 and a
single inclination sensor 10200, example embodiments may also
include systems with multiple distance sensors 10100 and multiple
inclination sensors 10200.
[0078] Example embodiments of the invention have been described in
an illustrative manner. It is to be understood that the terminology
that has been used is intended to be in the nature of words of
description rather than of limitation. Many modifications and
variations of example embodiments are possible in light of the
above teachings. Therefore, within the scope of the appended
claims, the present invention may be practiced otherwise than as
specifically described.
* * * * *