Patent application title:

CONTROL SYSTEM FOR COMPACTING MACHING HAVING BLADE

Publication number:

US20260168181A1

Publication date:
Application number:

18/979,245

Filed date:

2024-12-12

Smart Summary: A soil compactor is a machine designed to compress soil using a rotating drum. It has a blade that helps push or level the soil. Sensors monitor how well the blade is working and send this information to a controller. The controller then produces signals that show the blade's operating state. Additionally, the compactor includes a system to check the wear on parts that connect the drive mechanism to the drum, ensuring everything functions properly. 🚀 TL;DR

Abstract:

A soil compactor comprises a frame, a compaction drum rotatably mounted on the frame, a drive mechanism for rotating the compaction drum, a blade mounted to the frame to push or level loads, a first sensor configured to monitor operation of the blade, a controller configured to receive output of the first sensor, and an output system connected to the controller and configured to generate an output signal indicative of an operating state of the blade based on output of the first sensor. A soil compactor comprises a frame, a compaction drum rotatably mounted on the frame, a drive mechanism for rotating the compaction drum, a plurality of isolation mounts connecting the drive mechanism to the compaction drum, a monitoring system configured to monitor wear on the plurality of isolation mounts, and an output system configured to generate an output signal related to usage of the plurality of isolation mounts.

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Classification:

E01C19/288 »  CPC main

Machines, tools or auxiliary devices for preparing or distributing paving materials, for working the placed materials, or for forming, consolidating, or finishing the paving for consolidating or finishing laid-down unset materials; Rollers therefor; Such rollers usable also for compacting soil; Vibrated rollers or rollers subjected to impacts, e.g. hammering blows adapted for monitoring characteristics of the material being compacted, e.g. indicating resonant frequency, measuring degree of compaction, by measuring values, detectable on the roller; using detected values to control operation of the roller, e.g. automatic adjustment of vibration responsive to such measurements

E01C19/286 »  CPC further

Machines, tools or auxiliary devices for preparing or distributing paving materials, for working the placed materials, or for forming, consolidating, or finishing the paving for consolidating or finishing laid-down unset materials; Rollers therefor; Such rollers usable also for compacting soil; Vibrated rollers or rollers subjected to impacts, e.g. hammering blows Vibration or impact-imparting means; Arrangement, mounting or adjustment thereof; Construction or mounting of the rolling elements, transmission or drive thereto, e.g. to vibrator mounted inside the roll

E01C19/28 IPC

Machines, tools or auxiliary devices for preparing or distributing paving materials, for working the placed materials, or for forming, consolidating, or finishing the paving for consolidating or finishing laid-down unset materials; Rollers therefor; Such rollers usable also for compacting soil Vibrated rollers or rollers subjected to impacts, e.g. hammering blows

Description

TECHNICAL FIELD

This present disclosure is generally directed to, but not by way of limitation, construction equipment such as compacting machines including soil compactors. More specifically, but not by way of limitation, the present disclosure is directed to vibratory compactors having isolation mounts to reduce transmission of vibrations to the machine frame.

BACKGROUND

Compactors are machines used to compact initially loose materials, such as asphalt, soil, gravel, and the like, to a densified and more rigid mass or surface. For example, soil compactors are utilized to compact soil at construction sites and on landscaping projects to produce a foundation on which other structures may be built. Most soil compactors include a rotatable roller drum that may be rolled over the surface to compress the material underneath. In addition to utilizing the weight of the roller drum to provide the compressive forces that compact the material, some compactors are configured to also induce a vibratory force to the surface.

The rotatable roller drum can be connected to the rest of the machine via isolation mounts. Isolation mounts can be configured to dampen transmission of vibrations from the roller drum to the frame of the machine. Isolation mounts can comprise bodies of resilient material. Isolation mounts typically have a finite lifespan, thereby requirement replacement at regular intervals.

Soil compactors can be provided with a blade or without a blade. A blade can be used for pushing soil ahead of the soil compactor as the compactor moves forward. Additionally, the blade can be used to move other obstructions, such as tree stumps, rocks and the like. Operation of the blade can affect the operation, maintenance, and safety of the soil compactor.

Examples of compactor machines are described in Pub. No. US 2022/0334581 A1 to Doy, titled “Method and System for Automated Implement Control”; Pub. No. US 2020/0019192 A1 to O’Donnell titled “Object Detection and Implement Position Detection System”; and Pat. No. US 11,868,114 B2 to McGee et al., titled “Transitioning Between Manned Control Mode and Unmanned Control Mode Based on Assigned Priority.”

SUMMARY

In an example, a soil compactor comprises a frame, a compaction drum rotatably mounted on the frame, a drive mechanism for rotating the compaction drum, a blade mounted to the frame that is configured to push or level loads, a first sensor configured to monitor operation of the blade, a controller configured to receive output of the first sensor, and an output system connected to the controller and configured to generate an output signal indicative of an operating state of the blade based on output of the first sensor.

In another example, a soil compactor comprises a frame, a compaction drum rotatably mounted on the frame, a drive mechanism for rotating the compaction drum, a plurality of isolation mounts connecting the drive mechanism to the compaction drum, a monitoring system configured to monitor wear on the plurality of isolation mounts, and an output system configured to generate an output signal related to usage of the plurality of isolation mounts.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic side view of a compactor machine with a monitoring and control system for a blade and isolation mounts according to various embodiments of the present disclosure.

FIG. 2 is a perspective side view of a compacting drum mounted to a drive plate via a plurality of isolation mounts and a blade engaged with a load.

FIG. 3 is a partial sectional front view of the compacting drum of FIG. 2 showing the isolation mounts.

FIG. 4 shows a schematic view of a monitoring, reporting and feedback system for a compacting machine of the present disclosure.

FIG. 5 is a block diagram illustrating methods for monitoring and controlling operation of a compacting machine having a blade implement, the methods configured to determine wear on isolation mounts for a compacting drum.

FIG. 6 is a block diagram illustrating methods for monitoring and controlling operation of a compacting machine having a blade implement, the methods configured to determine if the blade implement is improperly positioned.

In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.

DETAILED DESCRIPTION

FIG. 1 is a schematic side view of compacting machine 110 of the present disclosure comprising a monitoring, reporting and controlling system, such as system 200 of FIG. 4. Compacting machine 110 can comprise frame 112, blade 114, compacting drum 116, operator station 118 and traction devices 120.

Frame 112 can be supported relative to ground 160 by compacting drum 116 and traction devices 120. Traction devices 120 can comprise one or more wheels or tracks that can engage the ground or a work surface and rotate to provide motive force to compacting machine 110. Likewise, compacting drum 116 can additionally provide motive fore to compacting machine 110. In examples, frame 112 can include pivot point 121 between compacting drum 116 and traction devices 120 to allow compacting machine 110 to articulate. The portion of frame 112 connected to compacting drum 116 can comprise drum support 122A and drum support 122B (FIG. 2).

Blade 114 can be connected to drum support 122A and drum support 122B (FIG. 2) via arm 123A and another arm (not visible) on the opposite side of compacting drum 116. Arm 123A can be pivotally attached to the frame 112 at pivot connection 124. Blade 114 can be connected to hydraulic cylinder 126, which can be connected to frame 112 via blade mount 128. Hydraulic cylinder 126 can be used to raise and lower blade 114 as needed or desired by an operator.

Hydraulic system 130 of compacting machine 110 can supply hydraulic fluid to hydraulic cylinder 126, via one or more hydraulic valves and one or more pumps (not shown), for controllably changing a position of blade 114. Hydraulic system 130 can additionally provide hydraulic fluid to hydraulic motor 134, which can be used to rotate compacting drum 116. In additional examples, compacting machine 110 can also include propulsion unit 154, such as an internal combustion engine or electric motor. In examples, propulsion unit 154 can operate using hydraulic system 130.

Compacting machine 110 can be controlled by a machine control unit, such as controller 170. Controller 170 can comprise, for example, an electronic control module (ECM). Controller 170 can include one or more computer readable memory devices and one or more processors, and can enable compacting machine 110 to transition between a manned control mode, a remote control mode, and an autonomous control mode. Controller 170 can additionally be connected to the various sensors, monitoring devices, observations devices described herein to provide feedback and control operations for compacting machine 110.

Compacting drum 116 can be connected to input plate 136. Compacting drum 116 can additionally be connected to hydraulic motor 134 via drive plate 138. Drive plate 138 can be connected to compacting drum 116 via isolation mounts 180A through isolation mounts 180D (FIGS. 2 and 3). In the illustrated example, compacting machine 110 can have compacting drum 116 that includes a vibration mechanism, as described herein. However, compacting machine 110 can include other types of compacting drums, such as those without vibration mechanisms. In examples, compacting machine 110 can include a plurality of drums similar to compacting drum 116, that do or do not include vibration functionality, a smooth drum (e.g., compacting drum 116 of FIG. 1), a drum including tamping feet (FIG. 2), etc. Although the present application is described with reference to compacting machine 110, the monitoring systems can be used with respect to a dozer, an excavator, a mining truck, and/or the like and other construction or work machines having implements, such as blades, that can be moved into multiple positions.

Seat 139 can be located in operator station 118. From seat 139, an operator of compacting machine 110 can operate various controls to operate hydraulic motor 134 and hydraulic cylinder 126 as well as other systems and components of compacting machine 110, including blade 114.

Compacting machine 110 can include perception device 140, which can comprise one or more of a camera, a laser scanning and/or a LiDAR device, and a radar device. Compacting machine 110 can also include locating device 142, such as a Global Positioning System (GPS) receiver and/or, a Global Navigation Satellite System (e.g., GLObalnaya NAvigatsionnaya Sputnikovaya Sistema [GLONASS]) receiver. Perception device 140 and locating device 142 can be configured to facilitate autonomous or remote operation of compacting machine 110.

Compacting machine 110 can also include one or more devices for monitoring various operations of compacting machine 110. For example, compacting machine 110 can comprise linear position sensor 144 and rotational position sensor 146 that detect a vertical position and rotational position of blade 114, respectively. Compacting machine 110 can comprise acceleration sensor 147 such as an inertial measurement unit, one or more of hydraulic pressure sensor 148 configured to detect a pressure of hydraulic fluid associated with hydraulic system 130, and/or other devices. Compacting machine 110 can additionally include presence sensor 150 connected to seat 139 to determine if an operator, e.g., a person, is located in operator station 118. Presence sensor 150 can comprise a weight sensor, switch, proximity sensor and the like. Compacting machine 110 can also include parking brake sensor 151 that can determine if a parking brake is activated to inhibit rotation of traction devices 120 or deactivated to allow free rotation of traction devices 120.

Compacting machine 110 can also include one or more devices for receiving remote commands and for facilitating autonomous operation of compacting machine 110. For example, compacting machine 110 can include a network communication device 152 for communicating with one or more instances of remote system 172 via network 174, such as the internet. Network communication devices 152 can be configured to receive commands for autonomous operation of compacting machine 110 that are generated by remote systems 172 and can provide information regarding a current operating state of compacting machine 110 to the remote system, including a geographic location of compacting machine 110, such as can be determined by locating device 142, an operating status of hydraulic system 130, a status of blade 114 and compacting drum 116 of compacting machine 110, speed, orientation, and/or acceleration of compacting machine 110, and other appropriate information. Output of any of the devices for monitoring compacting machine 110, such as perception device 140, locating device 142, linear position sensor 144, rotational position sensor 146, acceleration sensor 147, hydraulic pressure sensor 148, presence sensor 150 and parking brake sensor 151, can be transmitted over network 174 by network communication device 152 to remote system 172.

Compacting machine 110 can be configured for fully-autonomous operation, semi-autonomous operation, and/or remote operation. As used herein “autonomous” refers to both fully-autonomous and semi-autonomous modes of operation. Semi-autonomous operation includes independent operation of at least one component of compacting machine 110 (e.g., propulsion and steering or position of blade 114) while an operator within compacting machine 110 or at a remote location supervises operation of compacting machine 110. The supervising operator may also control one or more aspects of compacting machine 110 during this operation (e.g., a vibration of compacting drum 116, a position of blade 114), and may override autonomous commands. Fully-autonomous operation may not require supervision such that, in response to receiving a request initiated by an operator, compacting machine 110 may perform a task in a desired work area, such as compacting at least a portion of this area, without further intervention or input from the operator.

As shown in FIG. 1, blade 114 can be selectively positioned at a ground-engaging or work position at which blade 114 can contact ground 160, which can comprise soil or other material of a work area. This position can be useful for engaging this material in order to change a grade, or slope, of the material, for spreading material while compacting, or for preventing material from accumulating under compacting drum 116. However, blade 114 can be raised to a fully-raised position and positions therebetween where blade 114 does not contact ground 160. The raised positions can allow compacting machine 110 to compact soil, or other material, without significantly changing the grade of this material. Blade 114 can be raised along direction 162 (FIG. 1) by actuating hydraulic cylinder 126 and lowered by actuating hydraulic cylinder 126 in the opposite direction. In examples, blade 114 can be used to engage load 164 in the raised or lowered position depending on the type of load, e.g., soil pile, stump, rock, etc.

The devices for monitoring and measuring the various operational aspects of compacting machine 110, such as perception device 140, locating device 142, linear position sensor 144, rotational position sensor 146, acceleration sensor 147, hydraulic pressure sensor 148, presence sensor 150 and parking brake sensor 151, can be in communication with controller 170. In some examples, only one or various sub-combinations of perception device 140, locating device 142, linear position sensor 144, rotational position sensor 146, acceleration sensor 147, hydraulic pressure sensor 148, presence sensor 150 and parking brake sensor 151 can be used. Perception device 140, locating device 142, linear position sensor 144, rotational position sensor 146, acceleration sensor 147, hydraulic pressure sensor 148, presence sensor 150 and parking brake sensor 151 can be used to determine the operational state of blade 114, e.g., the position of blade 114, or whether blade 114 is actively or was previously pushing a load.

In examples, feedback regarding blade 114 can be used to enable or disable movement of compacting machine 110 if blade 114 is in an improper position. For example, if blade 114 if determined to be down and an operator attempts to move compacting machine 110, controller 170 can temporarily disable propulsion unit 154 from applying motive force to traction devices 120 until blade 114 is raised or a user confirms the status of blade 114 and compacting machine 110. If blade 114 is determined to be up and an operator attempts to leave compacting machine 110, controller 170 can provide an alert or warning to the user to prompt lowering of blade 114 for parking of compacting machine 110 or the user confirm the status of blade 114 and compacting machine 110.

In additional examples, feedback regarding blade 114 can be used to determine or evaluate wear on isolation mounts, e.g., isolation mounts 180A through isolation mounts 180D of FIG. 2), for compacting drum 116. For example, the position of blade 114 can be correlated to hydraulic pressure levels to determine if the isolation mounts have been subject to shocks or excessive or abnormal wear events. Additionally, the speed and inclination of compacting machine 110 can be correlated to the hydraulic pressure to determine or cross-check if compacting machine was operating under normal or typical conditions. Controller 170 can determine if shocks or excessive wear events have occurred and log such events so that the events can be used in evaluating the remaining useful life of the isolation mounts. Additionally, controller 170 can provide feedback to a user regarding undesirable use of blade 114 or disable operational aspects of compacting machine 110 to prevent or limit further occurrences of shocks or excessive wear events.

FIG. 2 is a perspective side view of compacting drum 116 of FIG. 1 showing isolation mounts 180A, isolation mounts 180B, isolation mounts 180C and isolation mounts 180D. FIG. 2 shows blade 114 engaged with load 164. FIG. 3 is a partial sectional front view of compacting drum 116 of FIG. 2 showing isolation mounts 180A and isolation mounts 180C. FIGS. 2 and 3 are discussed concurrently.

Drum support 122A can be connected to bracket 184 to which hydraulic motor 134 is mounted. Hydraulic motor 134 can be connected to gearbox 186, which can connect to drive plate 138. Hydraulic fluid lines 135 can be used to deliver hydraulic fluid to hydraulic motor 134 from hydraulic system 130. Drive plate 138 can connect to flange 187A and flange 187C extending from compacting drum 116 via isolation mounts 180A through isolation mounts 180D. Compacting drum 116 can comprise cylindrical body 188 that can have an inner surface from which flange 187A and flange 187C can extend radially inwardly.

Isolation mounts 180A can comprise block 190A and block 192A. Block 190A can include pin 194A and block 192A can include pin 196A. Block 190A and block 192A can comprise resilient material configured to dampen vibration emanating from cylindrical body 188 from travelling to drive plate 138 and on to frame 112.

Isolation mounts 180C can comprise block 190C and block 192C. Block 190C can include pin 194C and block 192C can include pin 196C. Block 190C and block 192C can comprise resilient material configured to dampen vibration emanating from cylindrical body 188 from travelling to drive plate 138 and on to frame 112.

In examples, block 190A, block 192A, block 190C and block 192C can be fabricated from rubber. Block 190A, block 192A, block 190C and block 192C can comprise dumbbell-shaped bodies between which guides 197 can pass when compacting drum 116 rotates.

Isolation mounts 180B and isolation mounts 180D can be configured similarly as isolation mounts 180A and isolation mounts 180C. For example, isolation mounts 180D can include block 190D and block 192D.

Vibration can be imparted to cylindrical body 188 from with vibration assembly 198. In examples, vibration assembly 198 can be configured according to conventional vibration assemblies, such as by rotation at high speeds of an eccentric weight within cylindrical body 188. In examples, vibration assembly 198 can be configured as described in Pat. No. US 8,967,910 B2 to Hansen et al., titled “Eccentric Weight Shaft for Vibratory Compactor,” the contents of which are incorporated herein in their entirety. In examples, vibration assembly 198 can be configured as described in Pub. No. US 2020/0087870 A1 to Stern et al., titled “Eccentric Weight System with Reduced Rotational Inertia for Vibratory Compactor,” the contents of which are incorporated herein in their entirety.

During operation of compacting machine 110, compacting drum 116 can be rotated by hydraulic motor 134. More specifically, hydraulic motor 134 can provide a rotational input to gearbox 186. Gearbox 186 can convey rotational output to drive plate 138. Drive plate 138 can transmit force to flange 187A and 187C through isolation mounts 180A and isolation mounts 180C, respectively. Flange 187A and flange 187C can impart rotation to cylindrical body 188. Thus, compacting drum 116 can be rotatably driven to provide motive force to compacting machine 110.

Additionally, compacting drum 116 can be vibrated by operation of vibration assembly 198. Thus, compacting drum 116 can be moved up-and-down with reference to FIGS. 1 through 3 to provide downward force to ground 160 (FIG. 1) to cause compaction of soil, in addition to the weight of compacting drum 116. As mentioned, isolation mounts 180A, isolation mounts 180B, isolation mounts 180C and isolation mounts 180D can be configured to prevent or limit transmission of vibrations originating at compacting drum 116 from extending outside of compacting drum 116, such as to gearbox 186, hydraulic motor 134, frame 112, etc. Block 190A through block 192D can have a finite life. That is, after being subject to a certain amount of vibration, block 190A through block 192D can be less effective and damping vibration and can be replaced during a maintenance operation. The life of block 190A through block 192D can be the longest when subject only to typical vibration from vibration assembly 198, e.g., normal loading. However, during operation of compacting machine 110, isolation mounts 180A, isolation mounts 180B, isolation mounts 180C and isolation mounts 180D can be subject to increased and/or additional loading, e.g., abnormal loading.

Isolation mounts 180A, isolation mounts 180B, isolation mounts 180C and isolation mounts 180D can be subject to a variety of additional loads, that can be considered excess, abnormal or additional to typical or normal loading. In examples, an operator of compacting machine 110 can use blade 114 to perform operations that result in additional, undesirable loading of isolation mounts 180A, isolation mounts 180B, isolation mounts 180C and isolation mounts 180D. As mentioned, blade 114 can be used to move soil in front of compacting machine 110. However, sometimes an operator can use blade 114 to attempt to move large objects, such as large tree stumps or large rocks. When compacting machine 110 is driven so that blade 114 is pushed into a large or heavy object, e.g., load 164, the operator can have a tendency to increase the propulsion of compacting machine 110 generated by hydraulic motor 134. Thus, hydraulic motor 134 can impart an increased amount of torque to compacting drum 116, which increases the load on isolation mounts 180A, isolation mounts 180B, isolation mounts 180C and isolation mounts 180D. Furthermore, the impact of blade 114 on load 164, be it large or otherwise, at high speed can cause a shock load to the hydraulic system, thereby generating a spike in hydraulic pressure. These loadings can impart larger deformations of isolation mounts 180A, isolation mounts 180B, isolation mounts 180C and isolation mounts 180D, which can reduce the useful life of isolation mounts 180A, isolation mounts 180B, isolation mounts 180C and isolation mounts 180D.

With the present disclosure, compacting machine 110 can include a monitoring, feedback and control system (e.g., system 200 of FIG. 4), such as can be operated by controller 170, that can use various inputs, such as from such as perception device 140, locating device 142, linear position sensor 144, rotational position sensor 146, acceleration sensor 147, hydraulic pressure sensor 148, presence sensor 150 and parking brake sensor 151, to evaluate usage and wear of compacting machine 110 and isolation mounts 180A through isolation mounts 180D and provide instructions to an operator and to compacting machine 110.

Hydraulic pressure sensor 148 can be used to monitor for elevated hydraulic pressure levels that are indicative of increased stress being placed on isolation mounts 180A, isolation mounts 180B, isolation mounts 180C and isolation mounts 180D. In particular, the increased hydraulic pressure can be indicative of undesirable or improper use of blade 114. In examples, hydraulic pressure sensor 148 can be used to sense increased pressure from hydraulic motor 134 and from hydraulic cylinder 126. In examples, an additional pressure sensor can be included on a hydraulic line for hydraulic cylinder 126.

However, increases in hydraulic pressure can occur during normal or not improper operation of compacting machine 110. For example, increases in hydraulic pressure can occur when blade 114 is being used to push piles of material. Additionally, compacting machine 110 can be operated while traversing an incline, which can result in increased hydraulic pressure levels.

In order to verify or cross-check whether or not increased pressure levels in the hydraulic system are a result of undesirable or improper use of blade 114, data from other inputs can be collected from compacting machine 110 during operation.

In examples, output of linear position sensor 144 and rotational position sensor 146 can be used to determine the position of blade 114. In particular, linear position sensor 144 and rotational position sensor 146 can be used to determine if blade 114 is in a position where it is likely being used or likely not being used. For example, output of linear position sensor 144 can be used to determine if blade 114 is in an elevated position above ground 160, which can be indicative that blade 114 is not being used to push a load, whereas if blade 114 is in a down position, it can be indicative of blade 114 being used to push a load. Rotational position sensor 146 can additionally be used to determine the height of blade 114 above ground 160.

Output of perception device 140 can be used to determine the position and orientation of blade 114. Thus, perception device 140 can also independently be used to determine if blade 114 is in a position where it is likely being used (e.g., in a down position) or likely not being used (e.g., in an up position). Additionally, video output of perception device 140 can be used to directly determine if blade 114 is being used in a high-wear application. That is, video output of perception device 140 can be used to observe blade 114 being impacted into an object. Output of perception device 140 can also be used to verify output of linear position sensor 144 and rotational position sensor 146. In examples, perception device 140 can comprise a video camera or a still picture camera, such as a photosensitive element, including a charge-coupled device (“CCD” sensor) or a complementary metal-oxide semiconductor (“CMOS”) sensor.

Output of acceleration sensor 147 can be used to determine the speed and acceleration of compacting machine 110. Output of acceleration sensor 147 can be used to verify output of hydraulic pressure sensor 148. For example, of acceleration sensor 147 determines that compacting machine 110 is operating at high speed while a spike in hydraulic pressure occurs, it can be indicative of an event where blade 114 has impacted a large or heavy load. In examples, acceleration sensor 147 can comprise an accelerometer. In examples, acceleration sensor 147 can additionally be used to determine the speed of compacting machine 110. In examples, acceleration sensor 147 can sense the rate at which compacting drum 116 is rotating.

Output of locating device 142 can additionally be used to determine the speed and acceleration of compacting machine 110. Output of locating device 142 can be used as an alternative to output of acceleration sensor 147. Output of locating device 142 can be used to verify output of acceleration sensor 147. Output of locating device 142 can additionally be used to determine the orientation of frame 112 of compacting machine 110, such as the inclination of compacting machine 110 when compacting machine 110 is traversing up a hill or down a hill, for example. In examples, one or more inclination or angle sensors can be used to sense the orientation, e.g., incline, of frame 112 directly without use of satellite signals. In examples, the inclination sensors can comprise a tilt sensor, a pendulum sensor and the like.

As discussed in greater detail with reference to FIG. 4, controller 170 can utilize output of Perception device 140, locating device 142, linear position sensor 144, rotational position sensor 146, acceleration sensor 147 and hydraulic pressure sensor 148 to provide feedback to a user of compacting machine 110, such as via output within operator station 118 or output via network communication device 152. The output can be used to log events and create histograms about the operation of compacting machine 110, which can be used to change operator behaviors, troubleshoot failures, and predict when replacement of isolation mounts 180A through isolation mounts 180D may be needed or desired. The output can be stored in memory (e.g., memory 177FIG. 4) of compacting machine 110 and communicated to a back office via network 174 (FIG. 1). Realtime monitoring of the output can be conducted in order to gain an indication of when it may be desirable to stop operation of an autonomous compacting machine in case of an encounter with an obstacle in the field of work.

Additionally, controller 170 can monitor the position of blade 114 using linear position sensor 144 and rotational position sensor 146, as well as output from presence sensor 150 and parking brake sensor 151 to determine if blade 114 is left in an undesirable or potentially unsafe position. For example, controller 170 can provide output to a user in operator station 118 to move blade 114 to a down position before exiting seat 139 or move blade 114 to an up position before moving compacting machine 110 or can disable movement of compacting machine 110 if blade 114 is not moved up before movement.

FIG. 4 shows a schematic view of system 200 configured for monitoring, controlling, reporting and providing feedback for compacting machine 110 of the present disclosure. System 200 can comprise perception device 140, locating device 142, linear position sensor 144, rotational position sensor 146, acceleration sensor 147, hydraulic pressure sensor 148, presence sensor 150 and parking brake sensor 151, as well as controller 170 and feedback device 176. Feedback device 176 can comprise audio output device 178A, mechanical dial 178B, haptic feedback device 178C and visual indicator 178D.

Output of perception device 140, locating device 142, linear position sensor 144, rotational position sensor 146, acceleration sensor 147, hydraulic pressure sensor 148, presence sensor 150 and parking brake sensor 151 can be provided to controller 170. Controller 170 can record such output to memory 177. Memory 177 can additionally include instructions for processing the output, generating reports based on the output, and generating instructions for operating elements of compacting machine 110.

Memory 177 can comprise a machine readable medium. The term “machine readable medium” can include any medium that is capable of storing, encoding, or carrying instructions for execution by controller 170 and that cause controller 170 to perform any one or more of the techniques of the present disclosure, or that is capable of storing, encoding or carrying data structures used by or associated with such instructions. Non-limiting machine-readable medium examples can include solid-state memories, and optical and magnetic media. In an example, a massed machine-readable medium comprises a machine readable medium with a plurality of particles having invariant (e.g., rest) mass. Accordingly, massed machine-readable media are not transitory propagating signals. Specific examples of massed machine-readable media can include: non-volatile memory, such as semiconductor memory devices (e.g., Electrically Programmable Read-Only Memory (EPROM), Electrically Erasable Programmable Read-Only Memory (EPSOM)) and flash memory devices; magnetic disks, such as internal hard disks and removable disks; magneto-optical disks; and CD-ROM and DVD-ROM disks.

Controller 170 can output pressure level signals from hydraulic pressure sensor 148 along a timescale. Controller 170 can additionally plot output from perception device 140, locating device 142, linear position sensor 144, rotational position sensor 146, acceleration sensor 147, presence sensor 150 and parking brake sensor 151 along the same time scale. As such, controller 170 can look for output from multiple sensor inputs that occur at the same time or that occur in the same time frame. Controller 170 can look for changes in the sensor output as well as rates of change of such output in order to determine and evaluate behavior, e.g., operating conditions, of compacting machine 110. In particular, controller 170 can identify operation of blade 114 in conjunction with compacting machine 110 to determine how blade 114 is being used, positioned or stored to provide feedback to a user of compacting machine 110, selectively and temporarily disable operation of portions of compacting machine 110 and generate reports relating to the predicted or estimated remaining life of wear components of compacting machine 110, such as drum isolation mounts.

In an example, controller 170 can receive an output from hydraulic pressure sensor 148 indicating operation of compacting machine 110 at elevated hydraulic pressure. In examples, hydraulic pressure sensor 148 can be used to sense hydraulic propel pressure of compacting machine 110. Thus, hydraulic pressure sensor 148 can be positioned on hydraulic fluid lines 135 connected to hydraulic motor 134. Thus, when hydraulic motor 134 is working harder, e.g., outputting more torque, hydraulic pressure sensor 148 can output a signal indicative of higher hydraulic pressure levels.

As explained herein, controller 170 can cross-reference the output of hydraulic pressure sensor 148 without output of other sensors and devices to determine an operating state of blade 114 and/or compacting machine 110. In particular, controller 170 can cross-reference the output of hydraulic pressure sensor 148 with output of linear position sensor 144 and rotational position sensor 146 to determine if blade 114 is in an up position or a down position in contact with or in close proximity to ground 160 (FIG. 1). If blade 114 is down and hydraulic pressure is up, this can be indicative that blade 114 is being used to push a large or heavy load that is placing additional load on the drive train, e.g., hydraulic system 130, hydraulic motor 134 and/or propulsion unit 154. Controller 170 can additionally look to other input to provide other points of reference. For example, controller 170 can determine if compacting machine is operating on level terrain or an inclined terrain, such as by using output of locating device 142 and/or an inclination sensor, tilt sensor or angle sensor.

If output of locating device 142 and/or an inclination sensor, tilt sensor or angle sensor indicates that compacting machine 110 is operating on inclined terrain while hydraulic pressure is up and blade 114 is down, controller 170 can determine that compacting machine 110 may be operating under normal conditions or conditions that are placing typical loading and wear on isolation mounts 180A through isolation mounts 180D. For example, compacting machine 110 may be using blade 114 to level a small pile of soil while traversing an incline in terrain.

If output of locating device 142 and/or an inclination sensor, tilt sensor or angle sensor indicates that compacting machine 110 is operating on level terrain while hydraulic pressure is up and blade 114 is down, controller 170 can determine that blade 114 may be operating under abnormal conditions or conditions that are placing additional loading and wear on isolation mounts 180A through isolation mounts 180D. For example, controller 170 can determine that blade 114 is being used to push a large or heavy object or load that blade 114 is not intended to move.

Additionally, output of perception device 140 and locating device 142 can be used to cross-check output of hydraulic pressure sensor. As mentioned, perception device 140 can provide an alternative to linear position sensor 144 and rotational position sensor 146 to determine the position of blade 114, or can be used to directly verify operation of blade 114 by providing images of blade 114 impacting load 164. Likewise, locating device 142 can be used as an alternative to acceleration sensor 147 and an inclination sensor.

The duration of the increase in hydraulic pressure can additionally be used determine or verify if blade 114 is being misused or used in an undesirable manner or in a manner that can cause increased wear on isolation mounts 180A through isolation mounts 180D. For example, a sudden increase in hydraulic pressure correlated with a sudden decrease in speed, as sensed by acceleration sensor 147, for example, of compacting machine 110 on flat ground while blade 114 is down can confirm or determine a likelihood that blade 114 has been used in an undesirable manner to impact a load and cause a wear event to occur on isolation mounts 180A through isolation mounts 180D. The sudden increase in hydraulic pressure can occur in the propulsion hydraulic pressure or in the pressure line for hydraulic cylinder 126. That is, controller 170 can cross-reference speed data and hydraulic pressure data that occurs simultaneous to determine that compacting machine 110 was operating at a speed above what is typically used for compacting operations while a contemporaneous spike in hydraulic pressure occurred indicating that blade 114 was impacted into a heavy load that compacting machine 110 may not have been able to move or may not have been able to move without additional work output.

In response to determining that blade 114 is or may be performing an undesired task or a task that places excessive loading on isolation mounts 180A through isolation mounts 180D, controller 170 can issue instructions to feedback device 176 to provide an alert or alarm to a user that controller 170 has detected a potential misuse of blade 114. In examples, feedback device 176 can include a display monitor, such as a touchscreen, LCD or LED screen and the like upon which a text message can be provided to the user to learn about the occurrence detected by controller 170. Additionally, controller 170 can provide an instruction to a component of compacting machine 110 to prevent or discourage the detected use of blade 114. For example, controller 170 can issue an instruction to hydraulic system 130, hydraulic motor 134 and propulsion unit 154 to prevent propulsion of compacting machine 110. In examples, controller 170 can issue an instruction to hydraulic cylinder 126 to move blade 114 into a position where blade 114 cannot be used. For example, controller 170 can be raised to an elevated position to prevent being engaged with objects close to ground 160. Additionally, controller 170 can initiate operation of a parking brake connected to parking brake sensor 151 to inhibit operation of traction devices 120 until corrective action is taken by a user. The disabling of propulsion of compacting machine 110, activation of the parking brake or the movement of blade 114 to a safe position can continue until a user acknowledges the warning displayed on feedback device 176. For example, feedback device 176 can issue a warning that impacting blade 114 into heavy objects can cause damage to isolation mounts 180A through isolation mounts 180D and that the user must acknowledge the discouraged use of such operation by pushing a button or touchscreen of feedback device 176 to permit further operation of compacting machine 110.

Additionally, controller 170 can log data from the sensors of system 200 into memory 177. Controller 170 can be configured to continuously record data or only record data when an event of interest occurs, e.g., an event where it is believed blade 114 is being improperly used or an event where excessive wear on isolation mounts 180A through isolation mounts 180D may be occurring. In examples, controller 170 can analyze output of the sensors of system 200 in real-time to identify events of interest to provide the desired feedback to the operator of compacting machine 110. In examples, data from the sensors of system 200 can be provided to remote system 172 in real-time for offboard analysis. In examples, data from the sensors of system 200 can be sent over network 174 in intervals, such after usage of compacting machine 110, e.g., after compacting machine 110 or propulsion unit 154 has been shut down. Reports generated by controller 170 or remote system 172 can be used to predict the remaining useful life of wear components of compacting machine 110, such as blade 114 and isolation mounts 180A through isolation mounts 180D. For example, memory 177 can include formulas and graphs or charts correlating output of hydraulic motor 134, e.g., torque output of hydraulic motor 134, to the expected life of isolation mounts 180A through isolation mounts 180D. Thus, when an increase in output of hydraulic motor 134 is detected that has been confirmed or cross-checked to relate to a load event on isolation mounts 180A through isolation mounts 180D, controller 170 can deduct time, e.g., usage time, from the remaining life of isolation mounts 180A through isolation mounts 180D. Thus, controller 170 or remote system 172 can generate computer readable files listing the usage history, impact events and remaining life of isolation mounts 180A through isolation mounts 180D. In examples, corrective action can be taken by a user of compacting machine 110 to replace isolation mounts 180A through isolation mounts 180D.

As discussed with reference to FIG. 6, output of presence sensor 150 and parking brake sensor 151 can be used to provide feedback to a user and change operation of compacting machine 110 based on the state or position of blade 114.

FIG. 5 is a block diagram illustrating method 300 for monitoring and controlling operation of compacting machine 110 having blade 114. In examples, method 300 can be configured to determine wear on isolation mounts 180A through isolation mounts 180D for compacting drum 116. Though discussed with reference to compacting machine 110 and system 200 and FIGS. 1 through 4, method 300 can encompass the use of any compacting machine and monitoring system consistent with the present disclosure. Method 300 can additionally include fewer or greater operations other than operation 302 to operation 324. Additionally, in other examples, operation 302 through operation 324 can be performed in other sequences.

At operation 302, hydraulic pressure of compacting machine 110 can be sensed. For example, hydraulic pressure sensor 148 can be used to sense the propel pressure of hydraulic system 130. Hydraulic pressure sensor 148 can continuously record the output of hydraulic pressure sensor 148 along a timescale for comparison to other data on a common timescale. Output of hydraulic pressure sensor can be recorded in memory 177.

At operation 304, the position of blade 114 can be sensed. For example, linear position sensor 144 and rotational position sensor 146 can be used to sense the position of blade 114. Linear position sensor 144 can directly sense the up or down position of blade 114 through the position of hydraulic cylinder 126. Rotational position sensor 146 can indirectly sense the up or down position of blade 114 through the position of arm 123A. Output of linear position sensor 144 and rotational position sensor 146 can be recorded in memory 177 along the common timescale with output of hydraulic pressure sensor 148.

At operation 306, the speed and/or acceleration of compacting machine 110 can be sensed. For example, acceleration sensor 147 or locating device 142 can be used to determine the speed and acceleration of compacting machine 110. Likewise, output of locating device 142 can be used to determine the speed, and acceleration of compacting machine 110. Output of acceleration sensor 147 and locating device 142 can be recorded in memory 177 along the common timescale with output of hydraulic pressure sensor 148.

At operation 308, the inclination of compacting machine 110 can be sensed. For example, locating device 142 or an inclination sensor be used to sense the incline or decline of frame 112 of compacting machine 110. Output of locating device 142 and an inclination sensor can be recorded in memory 177 along the common timescale with output of hydraulic pressure sensor 148.

At operation 310, a determination can be made if a load event has occurred. If an increase in the propulsion pressure, or another hydraulic pressure, of compacting machine 110 has been sensed, method 300 can move to operation 316. For example, controller 170 can determine a rise in hydraulic pressure has been sensed by hydraulic pressure sensor 148. If an increase in the propulsion pressure of compacting machine 110 has not been sensed, method 300 can move to operation 324.

At operation 312, the sensed hydraulic pressure, as can be indicated by propulsive force provided by hydraulic motor 134, can be compared to output of other sensed parameters of compacting machine 110 to verify or cross-check what may have caused the increase in hydraulic propulsion pressure. For example, the position of blade 114, the inclination of frame 112 and the speed and acceleration of compacting machine 110 as determined at operation 304, operation 306 and operation 308 can be used.

At operation 314, controller 170 can determine if the rise in hydraulic pressure caused a load event on isolation mounts 180A through isolation mounts 180D. If a load event has been determined to have occurred, method 300 can move to operation 316. For example, controller can determine that cross-checked information from operation 312 indicates the increase in hydraulic pressure was caused by loading of blade 114. If a load event has been determined to not have occurred, method 300 can move to operation 324. For example, controller can determine that cross-checked information from operation 312 does not indicate the increase in hydraulic pressure was caused by loading of blade 114.

At operation 316, the load event can be recorded in a log record. For example, output of perception device 140, locating device 142, linear position sensor 144, rotational position sensor 146, acceleration sensor 147, hydraulic pressure sensor 148, presence sensor 150 and parking brake sensor 151 can be recorded in memory 177.

At operation 317, the remaining useful life of a wear component of compacting machine 110 can be determined. Wear components can comprise blade 114 itself or a blade edged attached thereto and isolation mounts 180A through isolation mounts 180D. Controller 170 or remote system 172 can use predetermined formulas, equations and/or lookup tables that correlate total accumulated run time and hydraulic pressure to the useful life of isolation mounts 180A through isolation mounts 180D. If it is determined that the useful life of isolation mounts 180A through isolation mounts 180D has been exceeded or is near, controller 170 can output a warning using feedback device 176 and/or an operator of compacting machine 110 can perform a maintenance operation to replace isolation mounts 180A through isolation mounts 180D.

At operation 318, a warning or instruction can be provided to a user of compacting machine. The warning or instruction can be displayed on or transmitted by feedback device 176. In examples, the warning or instruction can convey to the user that a load event has occurred, and that the user should avoid operating compacting machine 110 in such a manner that caused the load event in the future. Examples of a load event can comprise running blade 114 into a heavy object at an elevated speed above normal operating speeds used for compacting soil or engaging blade 114 with a heavy object and increasing torque output of hydraulic motor 134 for a sustained period of time. Additionally, controller 170 can disable operation of compacting machine 110 or a portion thereof, such as blade 114 (by disabling linear position sensor 144 and/or rotational position sensor 146) or traction devices 120 (by activating a parking brake or disabling hydraulic motor 134).

At operation 320, it can be determined if a corrective action has been undertaken by the user. For example, controller 170 can determine a user has acknowledged the occurrence of the load event, such as by touching or engaging with controller 170 or feedback device 176. If it is determined that a corrective action has not yet occurred, method 300 can move back to operation 318. If a corrective action has been taken, method 300 can move to operation 322.

At operation 322, further operation of compacting machine 110 can be permitted. Any portion of compacting machine 110 that has been disabled can be reenabled. For example, a parking brake can be released to free-up traction devise 120 or hydraulic motor 134 can be reengaged.

At operation 324, compacting machine 110 can be operated to perform compacting operations with compacting drum 116 and leveling operations with blade 114. During usage of compacting machine 110, output of perception device 140, locating device 142, linear position sensor 144, rotational position sensor 146, acceleration sensor 147, hydraulic pressure sensor 148, presence sensor 150 and parking brake sensor 151 can be monitored and method 300 can return to operation 310.

FIG. 6 is a block diagram illustrating method 400 of operating compacting machine 110 to determine, verify and move the position of blade 114. Method 400 can determine if blade 114 is in an improper position for the current state of compacting machine 110. Improper positions for blade 114 can comprise blade 114 being up when compacting machine 110 is parked and blade 114 being down if compacting machine 110 is moving.

Though discussed with reference to compacting machine 110 and system 200 and FIGS. 1 through 4, method 400 can encompass the use of any compacting machine and monitoring system consistent with the present disclosure. Method 400 can additionally include fewer or greater operations other than operation 402 to operation 430. Additionally, in other examples, operation 402 through operation 430 can be performed in other sequences.

Method 400 can start while compacting machine 110 is actively being used, e.g., actively moving, or not actively being used, e.g., parked. Method 400 can begin at operation 402 if blade 114 is in a down position. Method 400 can begin at operation 404 if blade 114 is in an up position. Position of blade 114 can be determined by output of linear position sensor 144 and/or rotational position sensor 146, as well as perception device 140.

From operation 402, method 400 can move to operation 406 where controller 170 can determine if an operator is located in operator station 118. Controller 170 can use output of presence sensor 150 to determine if an operator is in operator station 118 and in particular seated in seat 139. If an operator is not sensed in operator station 118, method 400 can end since blade 114 is properly down for no operator being located in seat 139. If an operator is sensed in seat 139, method 400 can move to operation 408.

At operation 408, controller 170 can determine if parking brake sensor 151 is engaged or if it changes state. If parking brake sensor 151 determines that the parking brake is engaged or changes from not being engaged to being engaged, it can be indicative that the user intends to park compacting machine 110 and method 400 can end because blade 114 is already down. If parking brake sensor 151 indicates that the parking brake is disengaged or changes from engaged to disengaged, controller 170 can determine that there is a potential conflict in the desired operating state of compacting machine 110 in that the parking brake is off but blade 114 is down.

At operation 410, controller 170 can verify that blade 114 is down. As mentioned, output of linear position sensor 144, rotational position sensor 146 and/or perception device 140 can be used to determine the up or down state of blade 114. Down can comprise engaged with ground 160 and up can comprise disengaged with ground 160. Additionally, up and down can comprise when hydraulic cylinder is its extreme-most ends, e.g., either all the way extended, or all the way contracted.

At operation 412, controller 170 can receive a request from a user to put compacting machine 110 in motion. For example, a user seated in seat 139 can request that propulsion unit 154 provide motive action to traction devices 120. The user can push a button, depress a lever, depress a pedal, engage a user interface device, issue a voice command or the like to initiate activation of traction devices 120.

At operation 414, controller 170 can determine that compacting machine 110 may not be prepared for propulsion. Specifically, controller 170 can determine that compacting machine 110 is not ready to be moved with blade 114 in a lowered position, such as to contact ground 160. For example, if compacting machine 110 were moved with blade 114 down, blade 114 could potentially cause damage to a finished surface, e.g., a paved surface, or could potentially disrupt previously compacted soil or other material. Furthermore, movement of compacting machine 110 with blade 114 down could potentially cause damage to blade 114, particularly if engaged with a hard surface, such as concrete. Thus, controller 170 can temporarily disable or prevent propulsion unit 154 from applying motive action to traction devices 120. For example, controller 170 can prevent a command instruction from operator station 118 from reaching propulsion unit 154 or can activate a parking brake.

At operation 416, controller 170 can provide a notification to a user within operator station 118. The notification can inform the user that blade 114 is down and ask the user to confirm that movement of compacting machine 110 is desired with blade 114 down. For example, a display unit can provide a textual or graphical output that the user can read or view conveying to the user that blade 114 is in a down position.

At operation 418, the user can issue a command or enter an input into controller 170 to change the position of blade 114, such as to raise blade 114. Blade 114 can be raised a sufficient amount to allow movement, such as by being raised to disengage ground 160 or by being raised a minimum amount, such as four to twelve inches. Thereafter controller 170 can determine that compacting machine 110 is ready for movement and can reenable operation of propulsion unit 154.

At operation 420, the user can determine that it is desired to have compacting machine 110 move while blade 114 is down. For example, a user may intend to level a pile of soil in front of compacting machine 110 at the onset of movement of compacting machine 110. Thus, the user can override the instruction from controller 170 to disable propulsion unit 154.

After operation 418 or operation 420, method 400 can be completed and can return to the start of method 400.

As mentioned, method 400 can start at operation 404 if blade 114 is down. From operation 404, method 400 can move to operation 422.

At operation 422, controller 170 can determine if parking brake sensor 151 is disengaged or if it changes state. If parking brake sensor 151 indicates that the parking brake is disengaged or changes from engaged to disengaged, it can be indicative that the user intends to move compacting machine 110 and method 400 can end because blade 114 is already up. If parking brake sensor 151 determines that the parking brake is engaged or changes from not being engaged to being engaged, controller 170 can determine that there is a potential conflict in the desired operating state of compacting machine 110 in that the parking brake is on but blade 114 is up.

At operation 424, controller 170 can determine if an operator is located in operator station 118. Controller 170 can use output of presence sensor 150 to determine if an operator is in operator station 118 and in particular seated in seat 139. If an operator is sensed in operator station 118, method 400 can end since use of blade 114 may be in the process of being initiated while in the up position. If an operator is not sensed in seat 139, method 400 can move to operation 426.

At operation 426, controller 170 can verify that blade 114 is up. As mentioned, output of linear position sensor 144, rotational position sensor 146 and/or perception device 140 can be used to determine the up or down state of blade 114. Down can comprise engaged with ground 160 and up can comprise disengaged with ground 160. Additionally, up and down can comprise when hydraulic cylinder is its extreme-most ends, e.g., either all the way extended, or all the way contracted.

At operation 428, controller 170 can provide a notification to a user within operator station 118. The notification can inform the user that blade 114 is up while compacting machine 110 is parked, and ask the user to confirm that parking of compacting machine 110 is desired with blade 114 up. For example, a display unit can provide a textual or graphical output that the user can read or view conveying to the user that blade 114 is in an up position.

At operation 430, the user can issue a command or enter an input into controller 170 to change the position of blade 114, such as to lower blade 114. Blade 114 can be lowered to engage ground 160. Thereafter controller 170 can determine that compacting machine 110 is ready for parking and can shut-down, etc.

From operation 428, method 400 can move to operation 420. At operation 420, the user can determine that it is desired to have compacting machine 110 parked while blade 114 is up. For example, a user may intend to leave compacting machine 110 temporarily while have blade 114 raised, such as to allow maintenance to be performed. Thus, the user can override the instruction from controller 170 to provide a warning to the user, thereby clearing the warning and allowing compacting machine to be parked and shut-down.

After operation 430 or operation 420, method 400 can be completed and can return to the start of method 400.

INDUSTRIAL APPLICABILITY

Front leveling blades can be used on vibratory soil compactors (SCOMs). Leveling blade, which can be optional on certain models, can be used to knock down small piles of material or help move rocks or other obstructions from the area to be compacted.

The blade on an SCOM is configured as a leveling blade and is not of the same capability as a blade on a dozer. Leveling blades are typically intended to knock down piles of dirt left behind by dozer or motor grader and to move items from the compaction area that came in with the fill such as rocks of size generally no bigger than two inches in size and other similarly sized debris. Excessive and abusive use of the leveling blade beyond the applications noted herein may negatively affect the compacting machine. For example, an operator may run the compacting machine into big and heavy objects at a higher speed in an attempt to move the object. The operation can have negative effect on the life of the compacting drum isolation mounts and structures such as the blade, front frame, and hitch. Compacting drum isolation mounts are typically fabricated from a flexible, rubber material or component that isolates the vibratory action of the drum from the front frame. SCOMs can be equipped with drums that are driven so that the drum helps pull the SCOM through the soil. High levels of torque will be transferred through the drum due to excessive and abusive use of the leveling blade. That torque is transferred through the drum isolation mounts, which can result in large deflection between the input flange and output flange (e.g., flange 187A and flange 187C of FIG. 3) of the isolation mounts. This can lead to reduced component life. Drum isolation mounts comprise wear components in that they are typically replaced after a certain amount of usage. Thus, it can be beneficial for a customer to be able to predict and plan when these parts are ready to be replaced. Excessive loading of the isolation mounts can make predictability difficult.

When a leveling blade is heavily loaded, the blade will increase drive torque to the extent needed and up to what the machine is capable of in order to move the large, heavy object. The pressure in the hydraulic motor will correspondingly increase. This results in more torque going into the drum drive gearbox, which increases the output torque transferred through the drive plate and into the drum isolation mounts. The resistance to machine motion and the increased torque acting on the drum isolation mounts can result in larger deformations. This can reduce isolation mount life. Running the leveling blade into objects at a high speed can also result in similar overloading and reduction in isolation mount life. In addition, structural damage to the compacting machine can also occur.

The use of on-board machine date can monitor usage of the leveling blade. Using the various inputs, such as propel pressure, blade cylinder pressure, blade position, machine angle, machine speed, machine acceleration and others, can allow for recording of excessive, heavy, and abusive use of the blade.

Propel pressure can be sensed using pressure sensors from machine drive power system to give an indication of drivetrain load and rate of change of such. Blade cylinder pressure can be measured to provide feedback regarding load into the leveling blade, through the cylinder, and back to front frame. Blade position using a position sensing cylinder or camera system can be used to give indication of height of blade relative to ground or object. An angle sensor can be used to indicate if the compacting machine is working on a grade in order to understand if an increase in propel pressure is from blade usage or from working on an inclined slope. Machine speed sensors can be used to monitor changes in speed during the aforementioned conditions. Machine mounted accelerometers can be used to separately or in conjunction with other sensors to understand rates in machine acceleration. Additional sensors can be used to measure parameters to characterize blade usage.

Having high propel pressures when the blade is down, and machine is on flat ground can indicates heavy blade usage. Having sudden increases in propel pressure and sudden decrease in machine speed on flat ground when the blade is down indicates abusive blade usage. This information can be used to log events and create histograms about machine operation, which can be used to change operator behaviors, troubleshoot failures, and predict iso mount replacement. The information can be stored on the machine and communicated to a back office. Realtime monitoring of this can be an indication to stop the operation of an autonomous machine in case it encounters an obstacle in the field of work.

Another problem relates to positioning of the levelling blade on a soil compactor. The leveling blade can be mounted at the front of the vibratory soil compactor. The view of the operator of the front mounted blade is usually obstructed by the drum and front frame. In addition, the operator does not always know or think to check whether the blade is in the up or down position before commanding machine movement. When starting the machine movement, the operator can be unaware that the blade is in the down position, potentially resulting in damage to the blade, the machine or other objects and people in the vicinity, as the blade can strike various objects. Furthermore, the operator can leave the blade in the raised position when parking or leaving the machine. The blade can be a suspended load that is not mechanically secured and may fall to the ground due to an accidental cab command or other system malfunction.

The present disclosure provides a solution to these and other problems by providing an implement position indicator and machine interlock for a soil compactor. The implement position indicator system can indicate to an operator that the blade is detected in the down position, machine movement is requested after the presence of the operator is detected in the seat and the parking brake status changes from engaged to disengaged. In this case, machine movement can be prevented to avoid damage caused by the blade being in the down position, and the operator is acknowledged by an input from the operator, such as selecting a prompt on a display, or moving the blade up and then down again. In addition, if the blade is determined to be in the up position, no machine movement is detected, the parking brake status changes from disengaged to engaged, and the presence of the operator in the seat is not detected, an alert can be provided to the operator. Devices such as a position sensing hydraulic cylinder, electric switch, pressure sensor in the blade hydraulic circuit or camera can be used to determine the blade position and methods can be used to determine the park brake switch status, speed sensors on the drum/wheels and operator presence in the seat. In addition, operator messages can be logged and reported to the back office to indicate operator behavior.

Various examples are illustrated in the figures and foregoing description. One or more features from one or more of these examples may be combined to form other examples.

The above detailed description is intended to be illustrative, and not restrictive. The scope of the disclosure should, therefore, be determined with references to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the features, as claimed. As used herein, the terms “comprises,” “comprising,” “having,” including,” or other variations thereof, are intended to cover a non-exclusive inclusion such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements, but may include other elements not expressly listed or inherent to such a process, method, article, or apparatus. Moreover, in this disclosure, relative terms, such as, for example, “about,” “substantially,” “generally,” and “approximately” are used to indicate a possible variation of ±10% in the stated value.

Claims

What is claimed is:

1. A soil compactor comprising:

a frame;

a compaction drum rotatably mounted on the frame;

a drive mechanism for rotating the compaction drum;

a blade mounted to the frame that is configured to push or level loads;

a first sensor configured to monitor operation of the blade;

a controller configured to receive output of the first sensor; and

an output system connected to the controller and configured to generate an output signal indicative of an operating state of the blade based on output of the first sensor.

2. The soil compactor of claim 1, wherein:

the first sensor comprises a position sensor for the blade;

the controller is configured to determine if the blade is in an up position or a down position; and

the output system is configured to provide a first warning if the blade is in an up position and the soil compactor is parked or a second warning if the blade is in a down position and the soil compactor is about to move.

3. The soil compactor of claim 2, further comprising a presence sensor to determine if an operator is seated in an operator compartment of the soil compactor; wherein the first warning is issued when the presence sensor is not activated and the second warning is issued when the presence sensor is activated.

4. The soil compactor of claim 3, further comprising a parking brake sensor to determine if a parking brake is engaged or disengaged; wherein the first warning is issued when the parking brake sensor is engaged and the second warning is issued when the parking brake sensor is disengaged.

5. The soil compactor of claim 4, wherein the controller is configured to prevent operation of the drive mechanism if the blade is in a down position and an operator requests motion of the soil compactor.

6. The soil compactor of claim 4, wherein the controller includes an operator interface, and the controller is configured to solicit confirmation of a status of the blade to clear the first warning or the second warning.

7. The soil compactor of claim 1, wherein:

the drive mechanism comprises a hydraulic motor;

the first sensor comprises a pressure sensor; and

the compaction drum further comprises a plurality of isolation mounts connecting the drive mechanism to the compaction drum.

8. The soil compactor of claim 7, wherein the output signal is indicative of a wear event on the plurality of isolation mounts caused by the blade.

9. The soil compactor of claim 7, further comprising a second sensor selected from the group consisting of a speed or acceleration sensor and an inclination sensor, wherein the controller is configured to cross-check output of the second sensor before activating the output system to provide the output signal.

10. The soil compactor of claim 9, wherein the second sensor comprises the speed or acceleration sensor and the controller is configured to activate the output signal if the speed or acceleration sensor indicates an increase in speed when the increase in hydraulic pressure is sensed.

11. The soil compactor of claim 9, wherein the second sensor comprises an inclination sensor and the controller is configured to activate the output signal if the inclination sensor indicates operation on level ground.

12. The soil compactor of claim 1, wherein the output signal comprises an audio signal, a visual signal, a haptic feedback output, or a report stored on a computer readable medium.

13. A soil compactor comprising:

a frame;

a compaction drum rotatably mounted on the frame;

a drive mechanism for rotating the compaction drum;

a plurality of isolation mounts connecting the drive mechanism to the compaction drum;

a monitoring system configured to monitor wear on the plurality of isolation mounts; and

an output system configured to generate an output signal related to usage of the plurality of isolation mounts.

14. The soil compactor of claim 13, wherein:

the drive mechanism comprises a hydraulic motor connected to a hydraulic system; and

the monitoring system includes a pressure sensor for the hydraulic system.

15. The soil compactor of claim 14, further comprising:

a blade tool mounted to the frame;

wherein the monitoring system is configured to determine increases in pressure of the hydraulic system caused by the blade tool.

16. The soil compactor of claim 15, further comprising:

a vibration mechanism configured to impart vibratory motion to the compaction drum;

wherein the plurality of isolation mounts are configured to dampen vibration transmission from the compaction drum to the frame.

17. The soil compactor of claim 15, wherein the output signal comprises an audio signal, a visual signal or a haptic feedback output.

18. The soil compactor of claim 17, further comprising an operator interface configured to receive input from a user to clear the output signal from the output system.

19. The soil compactor of claim 13, wherein the monitoring system is configured to determine a remaining useful life of the plurality of isolation mounts.

20. The soil compactor of claim 19, wherein the output signal comprises a report stored on a computer readable medium.

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