COLD PLANER MILLING MACHINE TRUCK POSITION SENSOR SYSTEM

Description

TECHNICAL FIELD

The present disclosure relates to position sensing and guidance systems for cold planer milling machines and work trucks.

BACKGROUND

Cold planer milling machines are construction equipment used to remove layers of road surfaces through a milling process. These machines typically include a milling assembly and a conveyor system for transferring the milled material into transport vehicles. The conveyor system typically includes a secondary conveyor with a delivery end positioned above the transport vehicle to facilitate material transfer during operation. During milling operations, the cold planer moves forward continuously while transport vehicles, such as dump trucks, are positioned beneath the conveyor to receive the milled material. The coordination between the cold planer and transport vehicles requires precise positioning to ensure even distribution of milled material in the transport vehicle's container. Traditional cold planer systems employ various methods for coordinating movement between the milling machine and transport vehicles, including visual signals, audible signals, and automated guidance systems.

U.S. Pat. No. 9,562,334 discloses a sensor camera for detecting truck position, however, the patent does not disclose a mechanical actuator arm that physically contacts the truck to detect position. There is therefore a need for an improved cold planer milling machine truck position sensor system.

SUMMARY

This document discloses methods, systems, and apparatuses for sensing position of a cold planer milling truck or loading truck during material loading operations. The system includes an actuator arm that hangs down from a secondary conveyor of the milling assembly, configured to accommodate different truck box sizes and styles. The actuator arm reacts to contact with the tailgate or rear of the milling truck through movement and varying angle measurements, which are detected using linear transducers, inclinometers, rotary position sensors, proximity switches or combinations thereof. Based on predetermined angle measurements, the system triggers display lights visible to the truck driver to indicate when to stop or move forward for even load distribution. The system can be integrated with machine software for enhanced control options and is designed to be universal, requiring only power and ground connections for installation on any make or model of cold planer. This automated guidance system helps reduce operator workload and improves safety by eliminating the need for traditional horn signal communication between the cold planer operator and truck driver.

In some implementations, a position sensing system integrates with a secondary conveyor to detect and guide transport vehicle positioning during material delivery operations. An actuator arm extends down from the conveyor and makes physical contact with the transport vehicle positioned adjacent. The system incorporates sensing technology through a combination of sensors, e.g., an inclinometer for angle detection, a rotary position sensor for movement tracking, a proximity sensor for distance measurement, or a string pot for displacement monitoring. These sensors are protected within a component housing mounted to the conveyor structure. When the actuator arm contacts and moves in response to the transport vehicle, the sensors detect this interaction and generate position data. Forward-facing lights mounted on the conveyor's side provide visual signals to the vehicle operator. A controller processes the sensor data and activates these lights to guide the operator with movement instructions, enabling precise vehicle positioning during material transfer operations.

In some implementations, a position sensing system integrates sensing technology with a secondary conveyor to detect transport vehicle positioning during operations. A protective component housing is mounted to the conveyor and contains an array of sensor options, e.g., an inclinometer that measures angular displacement, a rotary position sensor that tracks rotational movement, a proximity sensor that detects distance, or a string pot that monitors linear displacement. An actuator arm extends downward from the conveyor and physically interacts with transport vehicles positioned adjacent to the delivery end. When the actuator arm contacts a vehicle, the resulting movement generates sensor data as it shifts relative to the conveyor structure. The system processes the sensor inputs through a controller that analyzes the movement patterns and position changes detected by the equipped sensors. This sensor integration enables the controller to determine the precise positioning of the transport vehicle based on the actuator arm's interactions, providing accurate position monitoring during material transfer operations.

In some implementations, transport vehicle positioning is monitored during material transfer operations. An actuator arm extends from a conveyor and makes physical contact with the transport vehicle. When contact occurs, sensors such as inclinometers, rotary position sensors, proximity sensors, or string pots detect and measure the actuator arm's movements and angular changes. The system analyzes these measurements to determine the precise position of the transport vehicle relative to the conveyor's delivery end. Based on this position data, the system activates forward-facing lights mounted on the conveyor to provide clear visual guidance to the vehicle operator, enabling precise positioning adjustments during material transfer. This automated guidance approach replaces traditional horn signal methods, streamlining communication between the conveyor operator and transport vehicle driver while improving operational safety and efficiency.

BRIEF DESCRIPTION OF THE DRAWINGS.

FIG. 1 is a drawing that illustrates an example position sensing system, in accordance with some aspects of the present technology.

FIG. 2 is a drawing that illustrates an example position sensing system, in accordance with some aspects of the present technology.

FIG. 3A is a drawing that illustrates an example position sensing system, in accordance with some aspects of the present technology.

FIG. 3B is a drawing that illustrates an example position sensing system, in accordance with some aspects of the present technology.

FIG. 3C is a drawing that illustrates an example position sensing system, in accordance with some aspects of the present technology.

FIG. 3D is a drawing that illustrates an example position sensing system, in accordance with some aspects of the present technology.

FIG. 4A is a drawing that illustrates an example position sensing system, in accordance with some aspects of the present technology.

FIG. 4B is a drawing that illustrates an example position sensing system, in accordance with some aspects of the present technology.

FIG. 4C is a drawing that illustrates an example position sensing system, in accordance with some aspects of the present technology.

FIG. 5A is a drawing that illustrates an example position sensing system, in accordance with some aspects of the present technology.

FIG. 5B is a drawing that illustrates an example position sensing system, in accordance with some aspects of the present technology.

FIG. 6 is a flowchart that illustrates an example process for a position sensing system, in accordance with some aspects of the present technology.

FIG. 7 is a block diagram that illustrates an example of a computer system in which at least some operations described herein can be implemented.

DETAILED DESCRIPTION

Cold planer milling machines are used in road construction to remove layers of road surfaces through a milling process, utilizing conveyor systems to transfer milled material into transport vehicles. The milling operation requires continuous forward movement while coordinating with transport vehicles positioned beneath the conveyor to receive milled material. Traditionally, coordination between cold planer operators and truck drivers has relied on audible horn signals, with one blast indicating stop and two blasts signaling forward movement. This conventional approach presents several challenges. The cold planer operator must simultaneously manage multiple responsibilities, including machine speed, tracking, obstacle awareness, and ground personnel communication, while also monitoring truck positioning. When truck drivers are unfamiliar with the signal system, miscommunication can occur, potentially leading to safety hazards and reduced machine uptime.

Disclosed herein is technology including a truck position sensing system that automates the coordination between cold planers and transport vehicles. The system includes an actuator arm that extends downward from a (secondary) conveyor of a cold planer, and is designed to accommodate various truck box sizes and styles. The actuator arm makes physical contact with the rear portion of a transport vehicle (box of truck) positioned adjacent to (e.g., below) the delivery end of the conveyor. The system can incorporate sensing technology through multiple sensor options, including linear transducers, inclinometers, rotary position sensors, and proximity switches. These sensors detect the movement and varying angle measurements of the actuator arm as it interacts with the truck box. The sensor data is processed by a control system that compares the detected angles against predetermined measurements set by the user.

Based on the analysis, the system activates a display light system mounted to the cold planer and visible to the truck driver. The lights provide visual signals indicating when the driver should stop or move forward, ensuring even load distribution without relying on traditional horn signals. The actuator arm can be configured in multiple mounting positions, including top-mounted and bottom-mounted options relative to the secondary conveyor frame. The system's components are housed in a protective enclosure, with a harness connecting the actuator to the signal lights. The actuator arm itself can be constructed from various materials, such as hydraulic hose or coated bar, designed to prevent damage to the truck tailgate during contact. The mechanisms that sense the position of the actuator arm are adjustable such that many different types of sensors can be used. The adjustability of the mechanisms enables the disclosed systems to be used on a variety of different work machines.

FIG. 1 is a drawing that illustrates an example position sensing system 108, in accordance with some aspects of the present technology. The environment shown by FIG. 1 includes a transport vehicle 104 positioned proximate to (e.g., below) a secondary conveyor 112 (e.g., of a cold planer machine). For example, the box of the transport vehicle 104 can be positioned 2 feet, 4 feet, 6 feet, 8 feet, 10 feet, etc., from the cold planer or the secondary conveyor 112. The secondary conveyor 112 has a delivery end configured to deliver milled material to the transport vehicle 104. In other implementations, the secondary conveyor 112 can belong to another work machine different from a cold planer.

The position sensing system 108 includes an actuator arm 116 that extends downward from the secondary conveyor 112 such that it can make physical contact with the transport vehicle 104 positioned adjacent to the delivery end. The position sensing system 108 incorporates a sensor system 132 housed within a component housing 120 mounted to the secondary conveyor 112. The sensor system 132 can include multiple sensor types that can work individually or together to detect movement of the cold planer and/or the transport vehicle 104 and varying angle measurements when the actuator arm 116 contacts the transport vehicle 104. The sensor system 132 can include an inclinometer for measuring angular displacement as the actuator arm 116 moves, a rotary position sensor for tracking rotational movement patterns, a proximity sensor for measuring distances between components, and a string pot for monitoring linear displacement of the actuator arm 116.

A signaling system 124 includes forward-facing lights 136 mounted to a side of the secondary conveyor 112. The lights 136 provide visual movement instructions including stop and forward commands to the transport vehicle operator based on the detected position, replacing traditional horn signals. The position sensing system 108 includes a controller 140 that receives position data 144 from the sensor system 132 based on the actuator arm's movement and varying angle measurements. The position data 144 can be digital or analog and can include comprehensive measurements from one or more sensor types. The controller 140 can include memory and/or analog or digital logic (implemented using the example computer system 700 shown by FIG. 7). The controller 140 processes the position data 144, for example, by comparing the detected angles against predetermined measurements and generates activation signals 148 to illuminate the appropriate forward-facing lights 136 to indicate truck movement instructions. The activation signals 148 generated by the controller 140 trigger the forward-facing lights 136 to illuminate based on the processed position data 144, enabling clear visual communication of stop and forward movement instructions to the transport vehicle operator during material transfer operations.

The actuator arm 116 can be constructed from hydraulic hose or coated bar material 128 specifically designed to prevent damage to the truck tailgate during contact. The actuator arm 116 is adjustable to accommodate different truck box sizes and styles, and can be mounted in either a centered configuration along the conveyor centerline or an offset position. The mounting system includes both top-mount and bottom-mount options to improve contact with different transport vehicle dimensions while maintaining the conveyor's primary material handling function.

The position sensing system 108 operates using a coordinated sequence of detection, processing, and signaling steps. When the actuator arm 116 contacts and moves in response to the transport vehicle 104, the integrated sensor system 132 detects this interaction through one or more coordinated measurements. The sensor system 132 generates comprehensive position data through individual or simultaneous operation of multiple sensor types: the inclinometer measures angular displacement as the arm 116 moves, the rotary position sensor tracks rotational movement patterns, the proximity sensor provides distance measurements, and/or the string pot monitors linear displacement of the actuator arm 116. The controller 140 receives this position data from the sensor system 132 based on the detected movements and varying angle measurements of the actuator arm 116.

The controller 140 analyzes the measurements by comparing the detected angles against predetermined measurements. This analysis enables precise determination of the transport vehicle's position relative to the conveyor's delivery end. Based on this position analysis, the controller 140 processes the sensor inputs and automatically activates the forward-facing lights 136 mounted on the conveyor to provide specific movement instructions to the truck driver. The signaling system 124 illuminates appropriate lights to indicate when the driver should stop or move forward, ensuring even load distribution. This automated guidance replaces traditional horn signals, with the lights providing clear, unambiguous visual commands that can be easily understood by all operators regardless of their familiarity with conventional signaling methods.

For example, the controller 140 uses angular displacement ranges from an inclinometer that indicate when the transport vehicle 104 is properly positioned. Rotational movement thresholds from the rotary position sensor can be used that trigger stop versus forward commands. Specific proximity sensor distances can be used to determine optimal vehicle positioning. String pot displacement measurements can be used that correspond to different loading positions. Predetermined angle measurements can be used by the controller 140 to determine when to activate specific lights

The position sensing system 108 maintains regular monitoring and updates the light signals in real-time as the actuator arm's position changes in response to truck movement, enabling precise vehicle positioning throughout the material transfer operation. This automated sequence significantly reduces operator workload while improving operational safety and efficiency. A harness can connect the sensor system 132 to the signaling system 124, with the harness being routed along the secondary conveyor 112 between the component housing 120 and the forward-facing lights 136. The entire system 108 requires only power and ground connections for installation, making it adaptable as a universal retrofit solution for any make or model of cold planer. In addition, the position sensing system 108, the sensor system 132, the signaling system 124, and the controller 140 that sense the position of the actuator arm 116 are adjustable such that many different types of sensors can be used. The adjustability of the disclosed mechanisms enables the system 108 to be used on a variety of different work machines (e.g., different types of cold planers, different types of excavators, work trucks, earthmovers, wheel loaders, and so on).

FIG. 2 is a drawing that illustrates an example position sensing system, in accordance with some aspects of the present technology. FIG. 2 shows the position sensing system's sensor integration and a mounting configuration. The system includes a secondary conveyor 112 with an actuator arm 116 extending downward to contact a transport vehicle positioned in a forward direction 200. The actuator arm 116 connects to the secondary conveyor 112 through a harness 204 that routes along the conveyor structure between the sensor components and signaling system. The mounting system utilizes a magnetic or toolless mount 208 that enables secure attachment while allowing the system to be folded when not in use. The actuator arm 116 contacts the box on the transport vehicle.

The sensor system is housed within the component housing 120 that can incorporate one or more sensing elements that can work individually or in concert. The component housing 120 can be mounted below the secondary conveyor 112 (sometimes referred to as a bottom mount option). For example, a rotary position sensor 212 tracks the actuator arm's rotational movement patterns as it responds to contact with the transport vehicle. Multiple proximity sensors 216 can provide distance measurements between the actuator arm 116 and vehicle components. A string pot 220 monitors linear displacement of the actuator arm 116 during operation, while an inclinometer 224 measures angular displacement as the arm 116 moves in response to vehicle contact.

The component housing 120 provides environmental protection for sensitive electronic elements while maintaining accessibility for maintenance. The housing 120 mounts securely to the secondary conveyor 112 and includes connection points for the harness 204 that carries sensor signals to a controller. The actuator arm 116 can be installed in either a top-mount or bottom-mount configuration relative to the secondary conveyor frame. The mounting system includes provisions for both centered positioning along the conveyor's centerline and offset arrangements to accommodate different operational requirements. This mounting flexibility enables the system to be adapted to various cold planer models while maintaining optimal contact with the transport vehicle.

The sensor integration shown by FIG. 2 enables position monitoring through one or more measurement methods. For example, the rotary position sensor 212 can work on its own or in conjunction with the proximity sensors 216 to track angular movement and distance changes. The string pot 220 provides linear displacement data while the inclinometer 224 monitors angular positioning, creating redundant measurement capabilities that ensure reliable position detection. The harness 204 provides protected routing for sensor signals between the component housing 120 and the system's forward-facing lights 136, ensuring reliable communication of movement instructions to transport vehicle operators. The forward-facing lights 136 can be mounted to the side of the cold planer.

The magnetic or toolless mount 208 facilitates both secure attachment during operation and easy removal when the system needs to be folded or serviced. This sophisticated sensor integration and mounting system enables precise position detection through physical contact rather than visual sensing, providing reliable guidance for transport vehicle positioning during material transfer operations. The system requires only power and ground connections for installation, making it a universal solution that can be retrofitted to any make or model of cold planer while maintaining comprehensive position monitoring capabilities.

FIG. 3A is a drawing that illustrates an example position sensing system, in accordance with some aspects of the present technology. FIG. 3A illustrates a bottom view of a bottom mount option for the position sensing system showing the interaction between the secondary conveyor 112 and actuator arm 116 and a forward direction 200. The secondary conveyor frame 304 provides the primary mounting structure for the position sensing components. The actuator arm 116 extends downward from the secondary conveyor 112 and includes an upper section that connects to the mounting system. The actuator arm's design enables it to make physical contact with the transport vehicle while maintaining proper clearance during operation.

The mounting configuration shown demonstrates how the actuator arm 116 integrates with the secondary conveyor frame 304 to maintain positioning relative to the transport vehicle. This arrangement allows the system to accommodate different truck box sizes and styles while ensuring reliable position detection. The mounting system includes provisions for both top-mount and bottom-mount options, providing installation flexibility while preserving the conveyor's primary material handling function. The actuator arm 116 connects to the sensor system housed within the component housing, which can contain multiple sensor types.

The mounting arrangement maintains proper clearance and operational capabilities while enabling the actuator arm to effectively track transport vehicle positioning during material transfer operations. The forward direction 200 indicator ensures proper system orientation during installation and operation. The configuration shown enables position detection while protecting both the sensing system components and the transport vehicle during operation.

FIG. 3B is a drawing that illustrates an example position sensing system, in accordance with some aspects of the present technology. FIG. 3B shows a side view of the secondary conveyor 112 and two optional actuator arm configurations while interfacing with a transport vehicle 104. The secondary conveyor frame provides the primary mounting structure for the system components while enabling material delivery to the box of the transport vehicle 104. In each configuration, the actuator arm extends downward from the secondary conveyor 112 and makes physical contact with the box of the transport vehicle 104 positioned adjacent to (e.g., below) the delivery end.

FIG. 3B shows an optional top mount option 312 that connects an actuator arm 116a above the secondary conveyor frame, providing clearance while maintaining effective contact with the transport vehicle 104. In this mounting configuration, the actuator arm 116a can be installed while preserving the conveyor's primary material handling capabilities. The material 308 being transferred flows along the secondary conveyor 112 while the position sensing system monitors the transport vehicle's location through physical contact. FIG. 3B also shows an optional bottom mount option 316 in which an actuator arm 116b is mounted at the bottom of the secondary conveyor. The box of the transport vehicle 104 shown by FIG. 3B is approaching the cold planer but has not made contact with the cold planer yet.

FIG. 3C is a drawing that illustrates an example position sensing system, in accordance with some aspects of the present technology. FIG. 3C illustrates a side view of the position sensing system showing the secondary conveyor 112, actuator arm 116, and a forward direction 200. The actuator arm 116 interfaces with a box of the transport vehicle 104. The secondary conveyor frame provides the primary mounting structure for the system components while enabling material delivery to the transport vehicle 104. The actuator arm 116 extends downward from the secondary conveyor 112 and makes physical contact with the transport vehicle 104 positioned adjacent to the delivery end. The system includes a bottom mount option that positions the actuator arm 116 below the secondary conveyor frame, providing an alternative mounting configuration while maintaining effective contact with the transport vehicle.

FIG. 3C shows that the actuator arm 116 has made physical contact with the box of the transport vehicle 104. The material 308 being transferred flows along the secondary conveyor 112 while the position sensing system monitors the transport vehicle's location through physical contact. The illustration demonstrates how the bottom mount configuration maintains consistent contact between the actuator arm and transport vehicle while accommodating the natural movement and positioning variations that occur during normal milling operations.

FIG. 3D is a drawing that illustrates an example position sensing system, in accordance with some aspects of the present technology. FIG. 3D illustrates a side view of the position sensing system showing the secondary conveyor 112 and actuator arm 116. The actuator arm 116 extends downward from the secondary conveyor 112 and makes physical contact with the transport vehicle 104 positioned adjacent to the delivery end. FIG. 3D shows the actuator arm 116 being pushed back further than it is in FIG. 3C.

FIG. 4A is a drawing that illustrates an example position sensing system, in accordance with some aspects of the present technology. FIG. 4A illustrates a top view of a top mount option of the position sensing system showing the integration of one or more sensor types within the component housing 120 mounted to the secondary conveyor 112. The system operates in a forward direction 200 and includes an actuator arm 116 that extends downward to make physical contact with transport vehicles. The component housing 120 contains a sophisticated array of sensors that can work individually or together to provide comprehensive position monitoring capabilities.

A rotary position sensor 212 tracks the actuator arm's rotational movement patterns as it responds to contact with the transport vehicle. The string pot 220 monitors linear displacement during operation, providing precise measurement of the actuator arm's position changes and movement relative to the secondary conveyor 112. An inclinometer 224 measures angular displacement as the arm 116 moves in response to vehicle contact, enabling accurate detection of varying angle measurements during operation. The sensor integration demonstrates how multiple measurement technologies can work in concert to provide redundant position monitoring capabilities through the combination of different sensor types.

The rotary position sensor 212 can work in conjunction with the string pot 220 to track both rotational movement and linear displacement, while the inclinometer 224 provides additional angular position data. This combination of sensors enables the system to maintain accurate position detection through physical contact rather than visual sensing methods. The component housing 120 provides environmental protection for these sensitive electronic elements while maintaining accessibility for maintenance and service. The housing 120 mounts securely to the secondary conveyor frame and includes connection points for the harness that carries sensor signals to the control system.

FIG. 4B is a drawing that illustrates an example position sensing system, in accordance with some aspects of the present technology. FIG. 4B illustrates a bottom view of a top mount option of the position sensing system showing the actuator arm 116 mounted to the secondary conveyor frame 304.

FIG. 4C is a drawing that illustrates an example position sensing system, in accordance with some aspects of the present technology. FIG. 4C illustrates a side view of a top mount option of the position sensing system showing the secondary conveyor frame 304 with the actuator arm 116 and the forward direction 200. The actuator arm 116 can be positioned in a centered configuration or an offset configuration relative to the secondary conveyor. In the centered actuator arm configuration, the arm 116 is positioned directly in line with the secondary conveyor's centerline, providing balanced contact with the transport vehicle during operation. In contrast, in the offset configuration, the actuator arm 116 can be positioned to one side of the secondary conveyor, offering installation flexibility while maintaining effective truck position sensing capabilities.

The component housing 120 can contain multiple sensor types working individually or together to provide comprehensive position monitoring regardless of the chosen actuator arm configuration. The string pot 220 monitors linear displacement during operation, providing precise measurement of the actuator arm's position changes relative to the secondary conveyor frame 304. These measuring components are strategically positioned to maintain accurate readings regardless of whether the actuator arm 116 is in a centered or offset arrangement. The rotary position sensor 212 and inclinometer 224 can work individually or together to provide comprehensive position monitoring in both centered and offset actuator arm configurations. For example, the rotary position sensor 212 tracks rotational movement patterns as the actuator arm 116 responds to contact with the transport vehicle, providing precise measurement of the arm's angular displacement relative to the secondary conveyor frame 304. The inclinometer 224 measures varying angle measurements as the actuator arm 116 moves in response to vehicle contact, working in conjunction with the rotary position sensor 212 to provide redundant angular position data. This dual sensor approach enables the system to maintain accurate position detection through physical contact rather than visual sensing methods. Both sensors are protected within the component housing 120 mounted to the secondary conveyor frame 304, with their outputs processed by a controller that analyzes the combined movement patterns and angular changes.

In some implementations, the sensor integration enables precise determination of transport vehicle positioning through individual or simultaneous monitoring of rotational movement via the rotary position sensor 212 and angular displacement via the inclinometer 224. This sophisticated sensor combination provides reliable position detection regardless of whether the actuator arm 116 is mounted in a centered or offset configuration. The system processes sensor inputs through a controller that analyzes the movement patterns and position changes detected by the equipped sensors in both mounting configurations. The sensor integration enables precise position detection through physical contact rather than visual sensing methods, providing reliable guidance for transport vehicle positioning during material transfer operations. In each of the centered and offset configurations, the system can effect consistent physical contact between the actuator arm 116 and the transport vehicle while accommodating the natural movement and positioning variations that occur during normal milling operations. This mounting flexibility enables the system to be adapted to various cold planer models while maintaining optimal contact with the transport vehicle.

FIG. 5A is a drawing that illustrates an example position sensing system, in accordance with some aspects of the present technology. FIG. 5A illustrates a top view of the position sensing system relative to the secondary conveyor 112. FIG. 5A shows an optional centered configuration including an actuator arm 116a positioned along the centerline of the secondary conveyor 112, providing balanced contact with the transport vehicle during operation.

FIG. 5A also shows an optional offset configuration in which an actuator arm 116b is off to one side of the secondary conveyor 112. The two alternate configurations enable improved positioning for standard material transfer operations while maintaining consistent contact with the transport vehicle. The centered mounting provides symmetrical loading and even distribution of forces during operation. In parallel, the offset configuration positions actuator arm 116b to one side of the secondary conveyor's centerline, offering installation flexibility for situations where centered mounting is not optimal. This offset arrangement maintains full position sensing capabilities while accommodating different machine layouts and operational requirements. Both configurations can integrate with the sensor system housed within the component housing. FIG. 5A shows how both mounting options maintain proper clearance and operational capabilities while enabling effective transport vehicle position tracking during material transfer operations.

FIG. 5B is a drawing that illustrates an example position sensing system, in accordance with some aspects of the present technology. FIG. 5B illustrates a side view of the position sensing system showing the secondary conveyor with two optional actuator arm configurations. In a centered configuration, the actuator arm 116a is positioned directly beneath the secondary conveyor, while in the offset configuration, the actuator arm 116b is in an offset mounting position. The centered configuration positions actuator arm 116a along the centerline of the secondary conveyor, providing balanced contact with the transport vehicle during material transfer operations. This configuration enables positioning while maintaining consistent contact between the actuator arm 116a and the transport vehicle. The centered mounting configuration can incorporate a full sensor array, including inclinometers, rotary position sensors, proximity sensors, and/or the string pot 220 to provide comprehensive position monitoring.

The offset configuration positions actuator arm 116b to one side of the secondary conveyor's centerline, offering installation flexibility for situations where centered mounting is not optimal. This configuration maintains full position sensing capabilities through sensor integration while accommodating different machine layouts and operational requirements. In each configuration the actuator arm connects to the sensor system housed within the component housing mounted to the secondary conveyor. The side view of FIG. 5B demonstrates how both mounting options maintain proper clearance and operational capabilities while enabling effective transport vehicle position tracking during material transfer operations.

FIG. 6 is a flowchart that illustrates an example process for a position sensing system, in accordance with some aspects of the present technology. In some implementations, the process is performed by the position sensing system 108 illustrated and described in more detail with reference to FIG. 1. A computer system 700 illustrated and described in more detail with reference to FIG. 7 performs some or all of the steps of the process in other implementations. Likewise, implementations can include different and/or additional steps or can perform the steps in different orders.

At 604, an actuator arm is positioned such that it extends downward from a conveyor system. This actuator arm is specifically designed to make physical contact with transport vehicles positioned adjacent to the conveyor's delivery end. The arm's positioning accommodates various truck box sizes and styles, allowing for versatile application across different transport vehicle configurations. The system can be installed in either a centered configuration along the conveyor's centerline or in an offset position, with both top-mount and bottom-mount options available to optimize contact with the transport vehicle. The actuator arm incorporates protective materials, such as hydraulic hose or coated bar construction, to prevent damage to the transport vehicle during contact while ensuring reliable position detection.

At 608, when the actuator arm makes contact with the transport vehicle, an integrated sensor system detects and measures the resulting movements and angular changes. The sensing technology can combine one or more sensor types - including inclinometers for angle detection, rotary position sensors for movement tracking, proximity sensors for distance measurement, and/or string pots for displacement monitoring. In some implementations, one or more sensor types work together to detect and measure the actuator arm's movement when it contacts the transport vehicle. For example, an inclinometer tracks angular displacement as the arm moves, while a rotary position sensor monitors rotational movement patterns.

A proximity sensor provides distance measurements, and a string pot tracks linear displacement of the actuator arm. These sensors are housed within a protective component enclosure mounted to the conveyor and work in concert to provide comprehensive movement data through mechanical contact rather than visual sensing. The combination of different sensor types enables redundant measurement capabilities, ensuring reliable and accurate position detection as the actuator arm responds to contact with the transport vehicle. As mentioned, these sensors are protected within a component housing mounted to the conveyor and work together to provide comprehensive movement data as the actuator arm responds to contact with the transport vehicle. The system captures varying angle measurements and movement patterns that occur when the actuator arm interacts with the vehicle, enabling precise position detection through mechanical contact rather than visual or projected energy sensing.

In some implementations, the actuator arm incorporates adjustable features that enable it to accommodate different truck box sizes and styles during operation. The system's design allows for flexible positioning through various mounting configurations, including both top-mount and bottom-mount options, to optimize contact with different transport vehicle dimensions. The actuator arm can be constructed from materials like hydraulic hose or coated bar that provide adaptable contact surfaces while preventing damage to different truck configurations. This adjustability ensures the system can maintain effective position sensing across a range of transport vehicle sizes while preserving the integrity of both the sensing system and the vehicles it monitors.

In some implementations, distinct mounting configurations can be implemented for installing the actuator arm on the conveyor structure. In the top mount configuration, the actuator arm is positioned above the secondary conveyor frame, while the bottom mount option places it below. Both mounting arrangements are designed to maintain proper contact with the transport vehicle while preserving the conveyor's primary material handling function. The mounting system includes provisions for secure attachment and component protection, with the actuator arm's position optimized for effective truck position detection regardless of the chosen mounting configuration. This flexibility in mounting options allows the system to be adapted to different cold planer models and operational requirements while maintaining reliable position sensing capabilities.

In some implementations, the actuator arm can be installed in either a centered configuration, where it aligns with the centerline of the secondary conveyor, or an offset configuration where it is positioned to one side of the conveyor's centerline. Both configurations maintain the arm's ability to contact and track transport vehicle position while accommodating different operational requirements. The centered arrangement provides balanced contact with the truck box directly beneath the conveyor, while the offset position offers installation flexibility when centered mounting may not be optimal. The system's sensors and control mechanisms function effectively in either configuration, ensuring reliable position detection regardless of whether the actuator arm is centered or offset relative to the conveyor structure.

At 612, the sensor data is processed to calculate the transport vehicle's position relative to the conveyor's delivery end. Multiple sensor inputs work together—the inclinometer provides angular displacement data, the rotary position sensor tracks movement patterns, the proximity sensor measures distances, or the string pot monitors linear displacement. The control system analyzes these varying measurements to determine exactly where the transport vehicle is positioned, enabling accurate tracking of the vehicle's location as it moves beneath the conveyor. This mechanical sensing approach provides more direct and reliable position detection compared to traditional vision-based systems, as it relies on physical contact measurements rather than projected energy sensing.

At 616, based on the determined position of the transport vehicle, forward-facing lights mounted on the side of the conveyor are activated to provide visual guidance to the vehicle operator. These lights signal specific movement instructions—such as stop and forward commands—replacing traditional horn signal methods. The signaling system processes the position data from the sensors and automatically illuminates the appropriate lights to guide the truck driver in achieving optimal positioning for even material distribution. This automated visual guidance system eliminates potential miscommunication issues that could arise with conventional audible signals, particularly when working with operators who may be unfamiliar with specific horn signal patterns.

In some implementations, the signaling system utilizes forward-facing lights mounted to the side of the conveyor to provide visual guidance to transport vehicle operators. When activated based on position data from the sensors, these lights illuminate in specific patterns to communicate movement instructions—such as stop and forward commands—replacing traditional horn signal methods. The lights are connected to the sensor system through a protective harness that routes along the conveyor from the component housing to the light mounting location. This visual signaling approach provides clear, unambiguous movement instructions that can be easily understood by all operators, regardless of their familiarity with conventional horn signal patterns.

Industrial Applicability

The disclosed apparatuses and systems have broad applicability across various construction and infrastructure development scenarios where material loading and transport operations are critical. The disclosed position sensing system demonstrates versatility beyond cold planer applications through its universal design that requires only power and ground connections for installation. The system's fundamental approach of using an actuator arm with integrated sensors to detect vehicle positioning can be adapted to any machine that requires coordinated material transfer operations. The system's flexible mounting configurations, including both top-mount and bottom-mount options, as well as centered and offset arrangements, allow it to accommodate various equipment layouts and operational requirements.

The protective design features, such as the coated actuator arm and enclosed component housing, ensure durability across different construction environments. This automated guidance system replaces traditional manual signaling methods with a reliable mechanical sensing approach, making it valuable for any construction scenario where precise positioning between material handling equipment and transport vehicles is critical. The system's ability to provide clear visual guidance while reducing operator workload makes it particularly beneficial for high-volume material transfer operations across various construction and infrastructure development applications.

The benefits and advantages of the implementations described herein include the universal design of the system, requiring only power and ground connections for installation on any make or model of cold planer. The disclosed systems can be implemented either as standalone retrofit solutions or integrated with machine software for enhanced control options. The disclosed automated guidance systems significantly reduce operator workload by eliminating the need for constant monitoring and manual signaling, while simultaneously improving overall safety and operational efficiency. The truck position sensing system offers several significant advantages over traditional methods of coordinating movement between cold planer operators and transport vehicles. By replacing conventional horn signal communication with an automated mechanical sensing system, the invention reduces the workload on cold planer operators who previously had to manage multiple responsibilities simultaneously, including machine speed, tracking, obstacle awareness, and ground personnel communication.

The system's actuator arm and integrated sensors provide reliable position detection through physical contact with the transport vehicle, eliminating potential miscommunication issues that could arise with traditional audible signals, especially when working with new truck drivers unfamiliar with specific signal patterns. The protective component housing and durable actuator arm construction, using materials like hydraulic hose or coated bar, ensure system longevity while preventing damage to transport vehicles during contact. Multiple sensor types working in concert—including inclinometers, rotary position sensors, proximity sensors, and string pots—provide redundant position monitoring capabilities, enhancing system reliability and accuracy. The forward-facing light system offers clear visual guidance to transport vehicle operators, improving operational safety by reducing the risk of miscommunication and potential accidents. Additionally, the system's flexibility in mounting configurations, including both centered and offset positions as well as top and bottom mounting options, allows for optimal installation based on specific equipment requirements and operational conditions. This comprehensive approach to position sensing and automated guidance leads to improved overall safety, increased machine uptime, and enhanced operational efficiency during milling operations.

FIG. 7 is a block diagram that illustrates an example of a computer system 700 in which at least some operations described herein can be implemented. Components of the computer system 700 can be used to implement the position sensing system 108 shown by FIG. 1.

As shown, the computer system 700 can include: one or more processors 702, main memory 706, non-volatile memory 710, a network interface device 712, video display device 718, an input/output device 720, a control device 722 (e.g., keyboard and pointing device), a drive unit 724 that includes a storage medium 726, and a signal generation device 720 that are communicatively connected to a bus 716. The bus 716 represents one or more physical buses and/or point-to-point connections that are connected by appropriate bridges, adapters, or controllers. Various common components (e.g., cache memory) are omitted from FIG. 7 for brevity. Instead, the computer system 700 is intended to illustrate a hardware device on which components illustrated or described relative to the examples of the figures and any other components described in this specification can be implemented.

The computer system 700 can take any suitable physical form. For example, the computer system 700 can share a similar architecture as that of a server computer, personal computer (PC), tablet computer, mobile telephone, game console, music player, wearable electronic device, network-connected (“smart”) device (e.g., a television or home assistant device), AR/VR systems (e.g., head-mounted display), or any electronic device capable of executing a set of instructions that specify action(s) to be taken by the computer system 700. In some implementation, the computer system 700 can be an embedded computer system, a system-on-chip (SOC), a single-board computer system (SBC) or a distributed system such as a mesh of computer systems or include one or more cloud components in one or more networks. Where appropriate, one or more computer systems 700 can perform operations in real-time, near real-time, or in batch mode.

The network interface device 712 enables the computer system 700 to mediate data in a network 714 with an entity that is external to the computer system 700 using any communication protocol supported by the computer system 700 and the external entity. Examples of the network interface device 712 include a network adaptor card, a wireless network interface card, a router, an access point, a wireless router, a switch, a multilayer switch, a protocol converter, a gateway, a bridge, bridge router, a hub, a digital media receiver, and/or a repeater, as well as all wireless elements noted herein.

The memory (e.g., main memory 706, non-volatile memory 710, machine-readable medium 726) can be local, remote, or distributed. Although shown as a single medium, the machine-readable medium 726 can include multiple media (e.g., a centralized/distributed database and/or associated caches and servers) that store one or more sets of instructions 728. The machine-readable (storage) medium 726 can include any medium that is capable of storing, encoding, or carrying a set of instructions for execution by the computer system 700. The machine-readable medium 726 can be non-transitory or include a non-transitory device. In this context, a non-transitory storage medium can include a device that is tangible, meaning that the device has a concrete physical form, although the device can change its physical state. Thus, for example, non-transitory refers to a device remaining tangible despite this change in state.

Although implementations have been described in the context of fully functioning computing devices, the various examples are capable of being distributed as a program product in a variety of forms. Examples of machine-readable storage media, machine-readable media, or computer-readable media include recordable-type media such as volatile and non-volatile memory devices 710, removable flash memory, hard disk drives, optical disks, and transmission-type media such as digital and analog communication links.

In general, the routines executed to implement examples herein can be implemented as part of an operating system or a specific application, component, program, object, module, or sequence of instructions (collectively referred to as “computer programs”). The computer programs typically include one or more instructions (e.g., instructions 704, 708, 728) set at various times in various memory and storage devices in computing device(s). When read and executed by the processor 702, the instruction(s) cause the computer system 700 to perform operations to execute elements involving the various aspects of the disclosure.