SYSTEM AND METHOD FOR INDICATING NON-IDEAL CONDITION OF DRUM OF COMPACTOR

Description

TECHNICAL FIELD

The present disclosure relates to a compactor, and more particularly, to a system for indicating a non-ideal condition of a drum of the compactor and a method for indicating the non-ideal condition of the drum of the compactor.

BACKGROUND

A compactor is typically used for compacting materials like asphalt, sand, aggregates, rocks, clay, concrete, or other such materials. The compactor includes one or more drums that contact the materials to be compacted. The drums may have a smooth outer shell, or the drums may be padded drums. Each drum is equipped with a vibration system that vibrates the corresponding drum at a desired vibrating frequency and a desired vibrating amplitude to compact the materials.

Drums of the compactor may wear away over a period of time due to interaction with the materials being compacted. For example, cracks may propagate in the drum with the smooth outer shell which may lead to an inoperable compactor and/or an inefficient compaction operation. Further, wear of a number of pads provided on padded drums may result in uneven support to the compactor as well uneven compaction. In some examples, materials that are being compacted by the compactor may accumulate on the outer shell of the drum or on the pads of the compactor. The accumulation of the materials may increase a mass of the drum, which may in turn decrease a vibratory amplitude of the drum. The decrease in the vibratory amplitude may reduce an effectiveness of a compaction operation being performed by the compactor and may require an increased number of passes to reach a compaction target.

U.S. Application Number 2020/0378554 describes a work machine that includes a compactor drum, a controller, and an output device. The compactor drum includes a vibratory system, which includes at least one bearing that supports rotation of the vibratory system within the compactor drum, and lubricant received by the at least one bearing. The controller is configured to monitor at least one physical property of the vibratory system over a specified time and project a remaining useful life of the lubricant based on the at least one physical property. The output device is configured to generate an output indicative of the remaining useful life.

SUMMARY OF THE DISCLOSURE

In an aspect of the present disclosure, a system for indicating a non-ideal condition of a drum of a compactor is provided. The system includes a sensor coupled to the drum of the compactor. The sensor is configured to generate a signal indicative of a current amplitude of vibration of the drum. The system also includes a controller. The controller includes one or more memories and one or more processors communicably coupled with each of the one or more memories and the sensor. The one or more memories are configured to store a nominal range for amplitude of vibration of the drum. The one or more processors are configured to receive, from the sensor, the signal indicative of the current amplitude of vibration of the drum. The one or more processors are also configured to compare the current amplitude of vibration with the nominal range for amplitude of vibration of the drum. The one or more processors are further configured to determine if the current amplitude of vibration is outside the nominal range for amplitude of vibration. The one or more processors are configured to generate an output signal if the current amplitude of vibration is outside the nominal range for amplitude of vibration. The output signal is indicative of the non-ideal condition of the drum of the compactor.

In another aspect of the present disclosure, a compactor is provided. The compactor includes a frame. The compactor also includes a drum coupled to the frame. The compactor further includes a system for indicating a non-ideal condition of the drum. The system includes a sensor coupled to the drum. The sensor is configured to generate a signal indicative of a current amplitude of vibration of the drum. The system also includes a controller. The controller includes one or more memories and one or more processors communicably coupled with each of the one or more memories and the sensor. The one or more memories are configured to store a nominal range for amplitude of vibration of the drum. The one or more processors are configured to receive, from the sensor, the signal indicative of the current amplitude of vibration of the drum. The one or more processors are also configured to compare the current amplitude of vibration with the nominal range for amplitude of vibration. The one or more processors are further configured to determine if the current amplitude of vibration is outside the nominal range for amplitude of vibration. The one or more processors are configured to generate an output signal if the current amplitude of vibration is outside the nominal range for amplitude of vibration. The output signal is indicative of the non-ideal condition of the drum of the compactor.

In yet another aspect of the present disclosure, a method for indicating a non-ideal condition of a drum of a compactor is provided. The method includes generating, by a sensor coupled to the drum of the compactor, a signal indicative of a current amplitude of vibration of the drum. The method also includes receiving, by one or more processors of a controller, the signal indicative of the current amplitude of vibration of the drum from the sensor. The method further includes comparing, by the one or more processors, the current amplitude of vibration with a nominal range for amplitude of vibration of the drum. One or more memories of the controller are configured to store the nominal range for amplitude of vibration of the drum. The method includes determining, by the one or more processors, if the current amplitude of vibration is outside the nominal range for amplitude of vibration. The method also includes generating, by the one or more processors, an output signal if the current amplitude of vibration is outside the nominal range for amplitude of vibration. The method further includes indicating the non-ideal condition of the drum of the compactor based on the generation of the output signal.

Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic perspective view of a compactor, according to an example of the present disclosure;

FIG. 2 is a schematic perspective view of a compactor, according to another example of the present disclosure;

FIG. 3 is a schematic perspective view of a block diagram of a system for indicating a non-ideal condition of a drum of the compactor of FIGS. 1 and 2, according to an example of the present disclosure; and

FIG. 4 is a flowchart of a method for indicating the non-ideal condition of the drum of the compactor of FIGS. 1 and 2, according to an example of the present disclosure;

DETAILED DESCRIPTION

Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

Referring to FIG. 1, a schematic perspective view of a compactor 100 is illustrated, according to an example of the present disclosure. The compactor 100 may be a soil compactor, an asphalt compactor, a concrete compactor, a landfill compactor, a pneumatic roller, a tandem vibratory roller, and the like. Further, the disclosure is not limited to a type of the compactor 100 and may include any other machine that includes one or more vibratory drums or vibratory members for which amplitude of vibrations can be measured.

The compactor 100 includes a frame 102. The frame 102 supports a number of components of the compactor 100 thereon. The compactor 100 defines a front end 104, and a rear end 106 opposite the front end 104. The compactor 100 further includes a pair of rear wheels 108.

The compactor 100 includes an enclosure 110. The compactor 100 also includes a power source (not shown) disposed within the enclosure 110. A number of components of the compactor 100 may be operated by the power source. The power source may be an engine, such as, an internal combustion engine, a fuel cell, a battery system, and the like, without limiting the scope of the present disclosure. The compactor 100 further includes an operator cabin 112. A user may be seated within the operator cabin 112 to perform and/or observe compaction operations.

The compactor 100 also includes a drum 120 coupled to the frame 102. The drum 120 is disposed at the front end 104 of the compactor 100. In another example, the compactor 100 may include a pair of front wheels disposed at the front end 104 and a drum disposed at the rear end 106 of the compactor 100. In yet another example, the compactor 100 may include a pair of drums, i.e., a first drum disposed at the front end 104 of the compactor 100 and a second drum is disposed at the rear end 106 of the compactor 100. Further, the drum 120 and the pair of rear wheels 108 together allow the compactor 100 to move over various surfaces.

In the illustrated example of FIG. 1, the drum 120 includes a drum shell 122 having a smooth outer surface 124. During a compaction operation, the drum shell 122 contacts materials to be compacted.

In some examples, the compactor 100 further includes a scraper 114. The scraper 114 may remove debris, dirt, or other foreign materials that may accumulate on the drum 120 during compaction operations. In some examples, the scraper 114 may include one or more plates to scrape out materials from the drum shell 122, without limiting the scope of the present disclosure.

Referring to FIG. 2, a schematic perspective view of a compactor 200 is illustrated, according to another example of the present disclosure. The compactor 200 is substantially similar to the compactor 100 (see FIG. 1), with common components being referred to by the same numerals. The compactor 200 includes a drum 220. However, in the illustrated example of FIG. 2, the drum 220 of the compactor 200 includes a drum shell 222 having a number of pads 226 on an outer surface 224 thereof. In other words, instead of the drum 120 (see FIG. 1) of the compactor 100 having the smooth outer surface 124 (see FIG. 1), the drum 220 includes the number of pads 226 projecting from and fixedly coupled to the outer surface 224.

The number of pads 226 may be disposed in any known pattern on the outer surface 224 of the drum 220. In the illustrated example of FIG. 2, each pad 226 has a circular shape. In other examples, each pad 226 may have any other shape known in the art, such as, a square shape, a rectangle shape, a pentagon shape, a hexagon shape, and the like, without limiting the scope of the present disclosure.

The compactor 200 also include a scraper 214. The scraper 214 may remove debris, dirt, or other foreign materials that may accumulate on the drum 220 during compaction operations. In some examples, the scraper 214 may include brushes to remove materials from the number of pads 226, without limiting the scope of the present disclosure. Alternatively, the scraper 214 may include individual scraper sections that may be made of materials, such as steel or iron. The individual scraper sections may fit between the pads 226.

Referring now to FIG. 3, a schematic perspective view of a block diagram of a system 300 for indicating a non-ideal condition of the drum 120, 220 of the compactor 100, 200 (see FIGS. 1 and 2) is illustrated. Specifically, the compactor 100, 200 includes the system 300 for indicating the non-ideal condition of the drum 120, 220. The system 300 can be associated with the compactor 100 having the drum 120 with the smooth outer surface 124 (see FIG. 1) or the compactor 200 having the drum 220 with the pads 226 (see FIG. 2).

The system 300 includes a sensor 302 coupled to the drum 120, 220 of the compactor 100, 200. The sensor 302 generates a signal 304 indicative of a current amplitude of vibration of the drum 120, 220. In an example, the sensor 302 may include a displacement sensor. The sensor 302 may include an accelerometer or an optical sensor. In some examples, the sensor 302 may be mounted at a vibratory side of isolation mounts (not shown) of the drum 120, 220. Further, the system 300 may include a single sensor or a pair of sensors.

It should be noted that the sensor 302 may include any type of sensor 302 and any number of sensors 302 that provides an indication of the current amplitude of vibration of the drum 120, 220, and the present disclosure is not limited to a type of the sensor 302 or the number of sensors 302. In some examples, when the compactor 100, 200 includes two drums, each drum will have a corresponding sensor to provide an indication of the current amplitude of vibration of the corresponding drum.

The system 300 also includes a controller 320. The controller 320 includes one or more memories 322. The one or more memories 322 store a nominal range for amplitude of vibration R1 of the drum 120, 220. The nominal range for amplitude of vibration R1 includes a minimum amplitude of vibration and a maximum amplitude of vibration.

The one or more memories 322 may include any means of storing information, including a hard disk, an optical disk, a floppy disk, ROM (read only memory), RAM (random access memory), PROM (programmable ROM), EEPROM (electrically erasable PROM), or other computer-readable memory media.

The controller also includes one or more processors 324. The one or more processors 324 are communicably coupled with each of the one or more memories 322 and the sensor 302.

It should be noted that the one or more processors 324 may embody a single microprocessor or multiple microprocessors for receiving various input signals and generating output signals. Numerous commercially available microprocessors may perform the functions of the one or more processors 324. The one or more processors 324 may further include a general processor, a central processing unit, an application specific integrated circuit (ASIC), a digital signal processor, a field programmable gate array (FPGA), a digital circuit, an analog circuit, a microcontroller, any other type of processor, or any combination thereof. The one or more processors 324 may include one or more components that may be operable to execute computer executable instructions or computer code that may be stored and retrieved from the one or more memories 322.

The one or more processors 324 receive the signal 304 indicative of the current amplitude of vibration of the drum 120, 220 from the sensor 302. The one or more processors 324 compare the current amplitude of vibration with the nominal range for amplitude of vibration R1 of the drum 120, 220. The one or more processors 324 determine if the current amplitude of vibration is outside the nominal range for amplitude of vibration R1. Specifically, the processors 324 may determine if the current amplitude of vibration is lesser than the minimum amplitude of vibration or if the current amplitude of vibration is greater than the maximum amplitude of vibration.

The one or more processors 324 further generate an output signal 330 if the current amplitude of vibration is outside the nominal range for amplitude of vibration R1. The output signal 330 is indicative of the non-ideal condition of the drum 120, 220 of the compactor 100, 200. Further, if the current amplitude of vibration is greater than the nominal range for amplitude of vibration R1, the output signal 330 is indicative of an increase in a wear of the drum 120, 220. Specifically, if the processors 324 determine that the current amplitude of vibration of the drum 120, 220 is greater than the maximum amplitude of vibration, the output signal 330 is indicative of the increase in the wear of the drum 120, 220.

Moreover, if the current amplitude of vibration is lesser than the nominal range for amplitude of vibration R1, the output signal 330 is indicative of an increase in an accumulation of the material on the drum 120, 220. Specifically, if the processors 324 determine that the current amplitude of vibration of the drum 120, 220 is lesser than the minimum amplitude of vibration, the output signal 330 is indicative of the increase in the accumulation of the material on the drum 120, 220.

The system 300 further includes an output module 340. The output module 340 is communicably coupled with the one or more processors 324. The output module 340 receives the output signal 330 from the one or more processors 324. The output module 340 generates a notification N1 to indicate the non-ideal condition of the drum 120, 220 of the compactor 100, 200 to a user. The user may be an operator or any personnel in-charge of the compactor 100, 200.

In some examples, the output module 340 may be a display screen, a speaker, a smartphone, a tablet, a light, a strobe, and the like. The output module 260 may be disposed inside the operator cabin 112 (see FIGS. 1 and 2). Alternatively, the output module 260 may be disposed outside the operator cabin 112, so that users present outside the compactor 100 may be notified of the non-ideal condition of the drum 120, 220. The notification N1 may be an audio message, a text message, a video message, or a combination thereof. For example, the notification N1 may include a text message regarding an increased wear of the drum 120, 220 if the processors 324 determine that the current amplitude of vibration of the drum 120, 220 is greater than the maximum amplitude of vibration. Alternatively, the notification N1 may include a text message regarding an increased accumulation of material on the drum 120, 220 if the processors 324 determine that the current amplitude of vibration of the drum 120, 220 is lesser than the minimum amplitude of vibration. In some examples, to indicate the non-ideal condition of the drum 120, 220, the output module 340 may trigger an alarm, a buzzer, or a light signal, without limiting the scope of the present disclosure.

In some examples, the one or more processors 324 receive a number of signals 304 indicative of an amplitude of vibration of the drum 120, 220 over a predetermined period of time. Further, the one or more processors 324 determine if the amplitude of vibration is outside the nominal range for amplitude of vibration R1 over the predetermined period of time. In an example, the processors 324 may determine an average amplitude of vibration of the drum 120, 220 based on the number of signals 304 received over the predetermined period of time. Further, the processors 324 may determine if the average amplitude of vibration of the drum 120, 220 is outside the nominal range for amplitude of vibration R1 over the predetermined period of time.

Further, the one or more processors 324 may generate the output signal 330 if the amplitude of vibration is outside the nominal range for amplitude of vibration R1 over the predetermined period of time. More particularly, the processors 324 may generate the output signal 330 if the current amplitude of vibration is lesser than the minimum amplitude of vibration over the predetermined period of time to indicate the increase in the accumulation of material on the drum 120, 220. Alternatively, the processors 324 may generate the output signal 330 if the current amplitude of vibration is greater than the maximum amplitude of vibration over the predetermined period of time to indicate the increase in the wear of the drum 120, 220.

It is to be understood that individual features shown or described for one embodiment may be combined with individual features shown or described for another embodiment. The above-described implementation does not in any way limit the scope of the present disclosure. Therefore, it is to be understood although some features are shown or described to illustrate the use of the present disclosure in the context of functional segments, such features may be omitted from the scope of the present disclosure without departing from the spirit of the present disclosure as defined in the appended claims

INDUSTRIAL APPLICABILITY

The present disclosure relates to the system 300 for indicating the non-ideal condition of the drum 120, 220. The system 300 includes the controller 320 which includes the one or more processors 324. The one or more processors 324 generate the output signal 330 if the current amplitude of vibration is outside the nominal range for amplitude of vibration R1. The system 300 further includes the output module 340 which receives the output signal 330. The output module 340 generates the notification N1 to indicate the user regarding the increase in the wear of the drum 120, 220, if the current amplitude of vibration is greater than the nominal range R1, or the increase in the accumulation of the material on the drum 120, 220, if the current amplitude of vibration is lesser than the nominal range R1.

In an example, the processors 324 compare the amplitude of vibrations with the nominal range R1 over the predetermined period of time to indicate the non-ideal condition of the compactor 100, 200. This approach may improve an accuracy of the system 300 by eliminating a one-off incident that may cause the current amplitude of vibration to be outside the nominal range R1.

The system 300 may be used to determine a remaining useful life of the drum 120, 220. The system 300 may alert the user that the drum 120, 220 may need to be examined, serviced, or replaced in order to maintain an efficiency of the compactor 100, 200. Furthermore, as the notification N1 generated by the system 300 may be used to determine if the drum 120, 220 needs to be serviced or replaced, the system 300 may allow servicing of the drum 120, 220 to be scheduled before the compactor 100, 200 become inoperable. In some cases, the system 300 may indicate an inadequate performance of the scraper 114, 214 due to, for example, an improper setting of the scraper 114, 214 or a defect, such as a worn-out condition, associated with the scraper 114, 214.

Moreover, the system 300 may prevent uneven compaction and material damage/wastage by generating the notification N1 to alert the user about the non-ideal condition of the drum 120, 220. In some cases, the system 300 may reduce repair costs, servicing timelines, and/or downtime of the compactor 100, 200 by alerting users regarding any damage to the drum 120, 220.

Overall, the system 300 is simple in construction and does not include complex components for operation. Further, the system 300 may improve an operating time and an efficiency of the compactor 100, 200. Furthermore, the system 300 may be cost-effective, may be retrofitted on existing compactors, and may be easy to install on compactors.

FIG. 4 is a flowchart for a method 400 for indicating the non-ideal condition of the drum 120, 220 of the compactor 100, 200. With reference to FIGS. 1 to 4, at step 402, the sensor 302 coupled to the drum 120, 220 of the compactor 100, 200 generates the signal 304 indicative of the current amplitude of vibration of the drum 120, 220.

At step 404, the one or more processors 324 of the controller 320 receive the signal 304 indicative of the current amplitude of vibration of the drum 120, 220 from the sensor 302.

At step 406, the one or more processors 324 compare the current amplitude of vibration with the nominal range for amplitude of vibration R1 of the drum 120, 220. The one or more memories 322 of the controller 320 store the nominal range for amplitude of vibration R1 of the drum 120, 220.

At step 408, the one or more processors 324 determine if the current amplitude of vibration is outside the nominal range for amplitude of vibration R1.

At step 410, the one or more processors 324 generate the output signal 330 if the current amplitude of vibration is outside the nominal range for amplitude of vibration R1.

At step 412, the non-ideal condition of the drum 120, 220 of the compactor 100, 200 is indicated based on the generation of the output signal 330.

The method 400 further includes a step (not shown) at which the one or more processors 324 receive the number of signals 304 indicative of the amplitude of vibration of the drum 120, 220 over the predetermined period of time. The method 400 further includes a step (not shown) at which the one or more processors 324 determine if the amplitude of vibration is outside the nominal range for amplitude of vibration R1 over the predetermined period of time. The method 400 further includes a step (not shown) at which the one or more processors 324 generate the output signal 330 if the amplitude of vibration is outside the nominal range for amplitude of vibration R1 over the predetermined period of time.

The method 400 further includes a step (not shown) at which the one or more processors 324 determine that the current amplitude of vibration is greater than the nominal range for amplitude of vibration R1 of the drum 120, 220. The method 400 further includes a step (not shown) at which the one or more processors 324 generate the output signal 330 to indicate the increase in the wear of the drum 120, 220 based on the current amplitude of vibration being greater than the nominal range for amplitude of vibration R1.

The method 400 further includes a step (not shown) at which the one or more processors 324 determine that the current amplitude of vibration is lesser than the nominal range for amplitude of vibration R1 of the drum 120, 220. The method 400 further includes a step (not shown) at which the one or more processors 324 generate the output signal 330 to indicate the increase in the accumulation of material on the drum 120, 220 based on the current amplitude of vibration being lesser than the nominal range for amplitude of vibration R1.

The output module 340 is communicably coupled with the one or more processors 324. The method 400 further includes a step (not shown) at which the output module 340 receives the output signal 330 from the one or more processors 324. The method 400 further includes a step (not shown) at which the output module 340 generates the notification N1 to indicate the non-ideal condition of the drum 120, 220 of the compactor 100, 200 to the user.

It should be noted that the steps 402, 404, 406, 408, 410, 412 of the method 400 may be performed in a sequence that is different from that explained in relation to FIG. 4. Further, various steps 402, 404, 406, 408, 410, 412 can be performed together.

While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed work machine, systems and methods without departing from the spirit and scope of the disclosure. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.