MATERIAL HANDLING SYSTEM

Abstract

A material handling system for a work machine includes a receptacle, an auger assembly, a conveyor system, and a material feed sensor configured to monitor an amount of the paving material. The material handling system further includes a controller configured to transmit, if a speed of the auger assembly and/or the conveyor system is not within a predetermined speed range and/or the amount of the paving material being directed towards the work surface is outside of a predetermined amount range, at least one of a control signal to the auger assembly and/or the conveyor system for adjusting the speed of the auger assembly and/or the conveyor system such that the speed of the auger assembly and/or the conveyor system lies within the predetermined speed range, and an alert notification to a user of the work machine to reposition the material feed sensor.

Description

TECHNICAL FIELD

The present disclosure relates to a material handling system for a work machine and a method for handling material by the work machine.

BACKGROUND

A work machine, such as a paving machine, may be used to receive, convey, distribute, profile, and compact paving material (e.g., asphalt). The paving machine includes a material feed system that may manage and direct the paving material to form a mat on a work surface or to form a uniform compacted surface that may have a variety of shapes depending upon job specification. The material feed system may include a receiving receptacle at a front end of the paving machine that accepts the paving material therewithin. The paving material in the receptacle is conveyed to a rear end of the paving machine by conveyors of the material feed system positioned at a base of the receptacle. The paving material is then distributed across a width of the paving machine by means of two opposing screws or augers of the material feed system. Finally, a screed assembly of the material feed system located at the rear end of the paving machine profiles and compacts the paving material into the mat or the uniform compacted surface.

If one or more components of the material feed system is malfunctioning, a component of the paving machine, such as a sensor, is not positioned accurately, an error is present in a computing system of the paving machine, or a setting of the paving machine is incorrect or unsuitable, to name a few examples, the resulting mat may have one or more defects. Defects of the mat may require that the mat be repaired, or in some cases, that the mat be removed and replaced entirely, thereby incurring additional time and resources which is not desirable. In some examples, one or more feeder sensors may be utilized to monitor the supply of the paving material. However, an incorrect position of the feeder sensor may result in erratic on/off operation of the material feed system, which may in turn cause a mat defect. Thus, an improved consistency in the delivery of the paving material may be helpful.

U.S. Pat. No. 11,127,135 describes a method that includes receiving sensor data indicative of a paved surface, and identifying a defect associated with the paved surface based at least in part on the sensor data. The method also includes determining that the defect is of a defect type based on determining that a value associated with the defect is within a value range associated with the defect type. The method further includes generating a command associated with the defect that, when executed by a machine, at least partially remedies the defect. The method also includes providing the command to an electronic device via a network.

SUMMARY OF THE DISCLOSURE

In an aspect of the present disclosure, a material handling system for a work machine is provided. The material handling system includes a receptacle for storing paving material. The material handling system also includes an auger assembly, at least a portion of which is in communication with the receptacle, and configured to direct the paving material from the receptacle for deposition on a work surface. The material handling system further includes a conveyor system configured to convey the paving material from the receptacle towards the auger assembly. The material handling system includes a material feed sensor disposed at an outer end of at least one of the auger assembly and the conveyor system. The material feed sensor is configured to monitor an amount of the paving material being directed towards the work surface. The material handling system also includes a controller communicably coupled to each of the auger assembly, the conveyor system, and the material feed sensor. The controller is configured to determine if a speed of at least one of the auger assembly and the conveyor system lies within a predetermined speed range. The controller is also configured to determine if the amount of the paving material being directed towards the work surface is outside of a predetermined amount range. The controller is further configured to transmit, if the speed of at least one of the auger assembly and the conveyor system is not within the predetermined speed range and/or the amount of the paving material being directed towards the work surface is outside of the predetermined amount range, at least one of a control signal to at least one of the auger assembly and the conveyor system for adjusting the speed of at least one of the auger assembly and the conveyor system such that the speed of at least one of the auger assembly and the conveyor system lies within the predetermined speed range, and an alert notification to a user of the work machine to reposition the material feed sensor.

In another aspect of the present disclosure, a method for handling material by a work machine is provided. The work machine includes a receptacle for storing paving material, an auger assembly, at least a portion of which is in communication with the receptacle, for directing the paving material from the receptacle for deposition on a work surface, a conveyor system configured to convey the paving material from the receptacle towards the auger assembly, and a material feed sensor disposed at an outer end of at least one of the auger assembly and the conveyor system and configured to monitor an amount of the paving material being directed towards the work surface. The method includes determining, by a controller, if a speed of at least one of the auger assembly and the conveyor system lies within a predetermined speed range. The method also includes determining, by the controller, if the amount of the paving material being directed towards the work surface is outside of a predetermined amount range. The method further includes transmitting, by the controller, if the speed of at least one of the auger assembly and the conveyor system is not within the predetermined speed range and/or the amount of the paving material being directed towards the work surface is outside of the predetermined amount range, at least one of a control signal to at least one of the auger assembly and the conveyor system for adjusting the speed of at least one of the auger assembly and the conveyor system such that the speed of at least one of the auger assembly and the conveyor system lies within the predetermined speed range, and an alert notification to a user of the work machine to reposition the material feed sensor.

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

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a work machine, according to an example of the present disclosure;

FIG. 2 is a schematic top view illustrating a portion of an auger assembly associated with the work machine of FIG. 1, according to an example of the present disclosure;

FIG. 3 is a block diagram of a material handling system for the work machine of FIG. 1, according to an example of the present disclosure;

FIG. 4 is an exemplary plot illustrating an operation of the auger assembly/conveyor system before and after transmitting the control signal, according to an example of the present disclosure;

FIG. 5 is an exemplary flowchart for a process executed by a controller of the material handling system of FIG. 3, according to an example of the present disclosure; and

FIG. 6 is a flowchart of a method for handling material by the work machine, according to an example of the present disclosure.

DETAILED DESCRIPTION

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

Referring to FIG. 1, a schematic perspective view of an exemplary work machine 100 is illustrated. The work machine 100 may perform one or more work operations associated with an industry, such as, mining, construction, farming, transportation, or any other industry known in the art. The work machine 100 is embodied as a paving machine herein. The work machine 100 may be used to receive, convey, distribute, profile, and compact paving material 104 on a work surface 102. The paving material 104 may include, for example, asphalt. Further, the work surface 102 may include, for example, a roadway. Alternatively, the work machine 100 may include any other type of machine, without any limitations.

The work machine 100 defines a first side 106 and a second side (not shown) opposite the first side 106. The work machine 100 includes a power source (not shown) that generates power. The power source may be an engine, such as, an internal combustion engine (e.g., a compression ignition diesel engine), or an electrically operated drive. The power source is enclosed within an enclosure 112. The work machine 100 also includes a number of ground engaging members 114. Although the ground engaging members 114 are illustrated as continuous tracks, it may be contemplated that the ground engaging members 114 may be of any other type, for example, wheels. Further, the work machine 100 includes a machine speed sensor 116 (shown in FIG. 3). The machine speed sensor 116 may include any conventional speed sensor known in the art that generates a signal indicative of machine speed.

The work machine 100 further includes an operator station 118. An operator of the work machine 100 may sit or stand in the operator station 118 to overlook ongoing operations. The operator station 118 may include various control devices that may be used for controlling one or more operations of the work machine 100. The control devices may include, but are not limited to, pedals, levers, switches, buttons, wheels, and other such devices known in the art. The work machine 100 includes a tractor portion 120 supported on the ground engaging members 114. The tractor portion 120 includes a tractor frame 122 as well as the power source. Further, the operator station 118 is coupled to the tractor portion 120.

As shown in FIGS. 1 and 2, the present disclosure relates to a material handling system 200 for the work machine 100. The material handling system 200 may be operated in an automated mode wherein the material handling system 200 may be used to lay a mat 128 on the work surface 102 based on feedback and/or inputs from various components thereof. In some examples, the material handling system 200 may operate in a closed loop manner. The material handling system 200 includes a receptacle 124 for storing the paving material 104.

The material handling system 200 associated with the work machine 100 also includes an auger assembly 202, at least a portion of which is in communication with the receptacle 124, to direct the paving material 104 from the receptacle 124 for deposition on the work surface 102. As used herein, the term “in communication” means paving material can be moved between a first component and a second component, whether directly or through the use of at least one additional component. The auger assembly 202 receives the paving material 104. Specifically, the auger assembly 202 is in communication with the receptacle 124 via a conveyor system 126 to direct and distribute the paving material 104 on the work surface 102.

Further, the auger assembly 202 includes a first auger portion 203 disposed at the first side 106 and a second auger portion (obstructed from view in FIG. 1) disposed at the second side. Each of the first auger portion 203 and the second auger portion may include one or more main augers. In an example, each of the first auger portion 203 and the second auger portion may include one main auger. In other examples, each of the first auger portion 203 and the second auger portion may include a main auger, and an auger extension coupled to the main auger via an auger bearing or other coupling component. The auger assembly 202 may distribute the paving material 104 across substantially an entire width of the work machine 100. The auger assembly 202 may be driven by a motor (not shown), such as, a hydraulic motor or an electric motor.

The material handling system 200 also includes a tunnel 130 for conveyance of the paving material 104 from the receptacle 124 to the auger assembly 202. The tunnel 130 may be disposed between the receptacle 124 and the auger assembly 202. The material handling system 200 also includes the conveyor system 126 for conveying the paving material 104 from the receptacle 124 towards the auger assembly 202. Specifically, the conveyor system 126 conveys the paving material 104 from the receptacle 124 towards the auger assembly 202, via the tunnel 130.

Further, as shown in FIG. 2, the material handling system 200 includes a material feed sensor 204 disposed at an outer end 206 of the auger assembly 202 and/or the conveyor system 126 (see FIG. 1). The material feed sensor 204 associated with the conveyor system 126 is shown in FIG. 1. It should be noted that the material handling system 200 may include multiple material feed sensors 204 that may be disposed at the outer end 206 of the auger assembly 202, the tunnel 130 (see FIG. 1), the receptacle 124 (see FIG. 1), an inlet end of the tunnel 130, or proximal to an end gate of a screed assembly 210 (see FIG. 1).

The material feed sensor 204 monitors the amount of the paving material 104 being directed towards the work surface 102 (see FIG. 1). The material feed sensor 204 generates a signal S1 (see FIG. 3) indicative of the amount of the paving material 104 being directed towards the work surface 102. By knowing the amount of the paving material 104 it may be possible to determine whether the paving material 104, fed by the conveyor system 126 and conveyed by first auger portion 203 is accumulating within the auger assembly 202, is being consumed faster than it can be replenished, or is in a steady state where the amount being consumed is the same as the amount being replenished. In an example, the material feed sensor 204 may include a sonic sensor. When the material feed sensor 204 includes the sonic sensor, the signal S1 may be indicative of a distance D1 of the material feed sensor 204 from the paving material 104. Alternatively, the material feed sensor 204 may be a mechanical paddle-type sensor, a camera system, or any other type of sensor.

A controller 228 (see FIG. 3) associated with the work machine 100 may modulate a flow and/or the amount of the paving material 104 based on the signal S1 received from the material feed sensor 204. Accordingly, the material feed sensor 204 needs to be positioned accurately to ensure that the material handling system 200 operates smoothly and continuously. In some examples, if the material feed sensor 204 is not positioned accurately, a quantity of the paving material 104 in front of the screed assembly 210 may vary which may in turn affect a paving depth PD1 (see FIG. 1) of the mat 128 (see FIG. 1) being formed, thereby forming a bumpy or unsmooth surface.

Further, a discontinuous or inconsistent operation of the material handling system 200 may also lead to the segregation of the paving material 104 before it passes underneath the screed assembly 210. Segregation in a paved surface may lead to premature failure of the paved surface. Further, the material feed sensor 204 may have to be aimed at a spot where the paving material 104 is constantly moving. If the material feed sensor 204 is aimed at a stationary/non-moving spot of the paving material 104, there may be a possibility of on/off operation of the material handling system 200. For example, when the material feed sensor 204 includes the sonic sensor, the material feed sensor 204 may have to be positioned accurately so that a pulse P1 of sound travelling towards the paving material 104 is reflected back to the material feed sensor 204. Typically, the pulse P1 needs to be perpendicular to a face 208 of the paving material 104. If the material feed sensor 204 is misaligned, the pulse P1 may bounce away from the material feed sensor 204 rather than directly back to the material feed sensor 204. When the material feed sensor 204 does not sense the pulse P1 returning from the paving material 104, the material feed sensor 204 may function erratically or not at all.

Referring to FIGS. 1 and 2, the material handling system 200 also includes the screed assembly 210 positioned downstream of the auger assembly 202 relative to a material movement direction D2. The screed assembly 210 spreads and compacts the paving material 104 into the mat 128 on the work surface 102. The work machine 100 further includes a pair of tow arms 212 which couples the screed assembly 210 to the tractor portion 120 so as to spread and compact the paving material 104 into the mat 128 on the work surface 102 (only one tow arm 212 is visible in FIG. 1). The screed assembly 210 further includes one or more actuators 214 (see FIG. 3). The actuators 214 may include a hydraulic actuator, an electric actuator, and/or any other type of actuator, as per application requirements. The actuators 214 may be controlled by the controller 228 (see FIG. 3). Alternatively, the actuators 214 may be controlled by any other onboard controller.

Referring now to FIG. 3, the material handling system 200 may include a speed sensor 216, 218 that generates a speed signal S2 indicative of a speed of the auger assembly 202 and/or the conveyor system 126, respectively. The speed of the auger assembly 202 and/or the conveyor system 126 may refer to a rotational speed of one or more components of the auger assembly 202 and/or the conveyor system 126, for example, as measured in revolutions per minute (RPM). The material handling system 200 further includes one or more screed width sensors 220 to generate a signal S3 indicative of a paving width (not shown) of the mat 128 (see FIG. 1). The screed width sensors 220 may include a combination of one or more gauges or sensors that may be used to determine the paving width of the mat 128. The material handling system 200 further includes a paving depth measuring device 222 to generate a signal S4 indicative of the paving depth PD1 (see FIG. 1) of the mat 128. The paving depth measuring device 222 may include a combination of one or more gauges or sensors that may be used to determine the paving depth PD1 of the mat 128.

The material handling system 200 further includes a grade control system 224. The grade control system 224 may maintain a pre-selected grade and/or slope with respect to a reference. The grade control system 224 may include one or more sensors for measuring a distance to the work surface 102 (see FIG. 1) from a reference point on the work machine 100. Such a sensor may include, for example, a wire rope sensor, a grade sensor, such as, an ultrasonic grade sensor, and the like.

Further, the material handling system 200 includes a user interface 226. The user interface 226 may be present within the operator station 118 (see FIG. 1) of the work machine 100. Alternatively, the user interface 226 may be present at a remotely located back-office. The user interface 226 may include one or more input means. For example, the input means may include physical input devices, such as, knobs, joysticks, buttons, levers, and the like. Further, the user interface 226 may include an output means, such as, a display screen that may provide output to the operator. In an example, the user interface 226 may include a touch screen device that may include the input and output means. Further, when the user interface 226 includes the touch screen device, the input means may include physical input means and/or virtual input means. Furthermore, the user interface 226 may include a tablet, a smartphone, and the like.

The material handling system 200 further includes the controller 228 communicably coupled to each of the auger assembly 202, the conveyor system 126, and the material feed sensor 204. Further, the speed sensor 216, 218 is communicably coupled to the controller 228. Furthermore, the controller 228 determines if the screed assembly 210 is in a float mode. The term “float mode” as used herein may mean that the tow arms 212 are allowed to pivot, permitting the screed assembly 210 to move in a manner that improves compaction of the paving material 104. In an example, the controller 228 may receive a signal from a valving of the actuators 214, or an electronic control module of the actuators 214 to determine if the screed assembly 210 is in the float mode. Moreover, the screed width sensor 220 is communicably coupled to the controller 228 to receive the signal S3 indicative of the paving width of the mat 128. The controller 228 is also communicably coupled with the paving depth measuring device 222, the grade control system 224, the machine speed sensor 116, and the user interface 226.

The controller 228 may be present onboard the work machine 100. In an example, the controller 228 may embody a central control unit associated with the work machine 100 that may be capable of controlling numerous machine functions. Alternatively, the controller 228 may embody an off-board controller. The controller 228 may embody a single microprocessor or multiple microprocessors for receiving various input signals from various components of the work machine 100. Numerous commercially available microprocessors may be configured to perform the functions of the controller 228. The controller 228 may include a central processing unit, a graphics processing unit, and the like. The controller 228 may also include a processing logic, such as, a field-programmable gate array (FPGA), an application-specific integrated circuit (ASIC), and the like.

The controller 228 may include one or more processors 230 and one or more memories 232. The memories 232 may include a flash memory, a random-access memory (RAM), an electrically erasable programmable read-only memory (EEPROM), and the like. The memories 232 may be used to store data, such as, algorithms, instructions, arithmetic operations, and the like. The processors 230 may execute various types of digitally stored instructions, such as, a software program or an algorithm, retrieved from the memories 232, or a firmware program which may enable the processors 230 to perform a wide variety of operations.

The controller 228 determines if the speed of the auger assembly 202 and/or the conveyor system 126 is over damped. Furthermore, the controller 228 transmits a filter signal to dampen the speed of the auger assembly 202 and/or the conveyor system 126 if the speed of the auger assembly 202 and/or the conveyor system 126 is over damped. In some examples, the controller 228 transmits the filter signal to dampen an over damped input signal that may be highly sinusoidal. Further, the controller 228 may determine if the user has enabled signal filtering of the auger assembly 202 and/or the conveyor system 126. Only if the user has enabled the signal filtering, the controller 228 may transmit the filter signal to dampen the speed of the auger assembly 202 and/or the conveyor system 126.

In an example, in order to determine if the speed of the auger assembly 202 and/or the conveyor system 126 is over damped, the controller 228 may receive the speed signal S2 from the speed sensor 216, 218, or may monitor an input signal to the auger assembly 202 and/or the conveyor system 126. The term “input signal” as used herein may relate to a speed signal that is sent by the controller 228 to the auger assembly 202 and/or the conveyor system 126. The input signal may indicate a speed value at which the auger assembly 202 and/or the conveyor system 126 is to be operated to achieve a desired outcome.

It should be noted that after the filter signal is transmitted, the speed of the auger assembly 202 and/or the conveyor system 126 may or may not lie within a predetermined speed range R1. Thus, after the transmission of the filter signal, the controller 228 determines if the speed of the auger assembly 202 and/or the conveyor system 126 lies within the predetermined speed range R1 (see FIG. 1). The controller 228 monitors the auger assembly 202 and/or the conveyor system 126 to determine if the speed of the auger assembly 202 and/or the conveyor system 126 lies within the predetermined speed range R1. In an example, in order to determine if the speed of the auger assembly 202 and/or the conveyor system 126 lies within the predetermined speed range R1, the controller 228 receives the speed signal S2 from the speed sensor 216, 218, respectively. Further, the controller 228 compares the speed signal S2 with the predetermined speed range R1 to determine if the speed of the auger assembly 202 and/or the conveyor system 126 lies within the predetermined speed range R1.

It should be noted that the speed signal S2 may be received from any other component or combination components of the material handling system 200, without any limitations. For example, the controller 228 may determine the speed of the auger assembly 202 and/or the conveyor system 126 based on the input signal sent to the auger assembly 202 and/or the conveyor system 126.

The controller 228 also determines if the amount of the paving material 104 being directed towards the work surface 102 (see FIG. 1) is outside of a predetermined amount range R2. For example, the controller 228 may determine if the paving material 104 being directed by the auger assembly 202 and/or the conveyor system 126 is less than a minimum amount or greater than a maximum amount, or if the amount of the paving material 104 is fluctuating at different instances of time. The predetermined speed range R1 and the predetermined amount range R2 may be stored in the memory 232 and retrieved by the processor 230, as and when required. Further, in some examples, the predetermined speed range R1 and the predetermined amount range R2 are configurable by a user via the user interface 226. For example, the user may update the predetermined speed range R1 and the predetermined amount range R2, as and when required based on operational characteristics, such as, an amount of the paving material 104 being handled by the work machine 100. The user may include the operator of the work machine 100 or a person in charge of a paving operation.

Further, the controller 228 transmits, if the speed of the auger assembly 202 and/or the conveyor system 126 is not within the predetermined speed range R1 and/or the amount of the paving material 104 being directed towards the work surface 102 is outside of the predetermined amount range R2, a control signal C1 to the auger assembly 202 and/or the conveyor system 126 for adjusting the speed of the auger assembly 202 and/or the conveyor system 126 such that the speed of the auger assembly 202 and/or the conveyor system 126 lies within the predetermined speed range R1 or an alert notification A1 to the user of the work machine 100 to reposition the material feed sensor 204. Moreover, in some examples, the alert notification A1 may also notify the user regarding the transmission of the filter signal to dampen the speed of the auger assembly 202 and/or the conveyor system 126. In some cases, if the speed of the auger assembly 202 is not consistent with the speed of the conveyor system 126, the speed of the conveyor system 126 may be updated by the controller 228. For example, if the speed of the auger assembly 202 is fast, the controller 228 may increase the speed of the conveyor system 126. Alternatively, if the speed of the auger assembly 202 is slow, the controller 228 may decrease the speed of the conveyor system 126.

In some examples, the controller 228 may transmit the control signal C1 to each of the auger assembly 202 and the conveyor system 126. In other examples, the controller 228 may transmit the control signal C1 to the auger assembly 202 or the conveyor system 126. Moreover, in some examples, the controller 228 may transmit each of the control signal C1 and the alert notification A1. In other examples, the controller 228 may first transmit the alert notification A1.

Referring now to FIGS. 3 and 4, in one example, the control signal C1 is transmitted to the motor(s) of the auger assembly 202 and/or the conveyor system 126. The control signal C1 may cause the auger assembly 202 and/or the conveyor system 126 to operate within the predetermined speed range R1 so that a difference between a minimum auger speed M1 and a maximum auger speed M2 is minimal and/or a difference between a minimum conveyor speed M3 and a maximum conveyor speed M4 is minimal. The term “minimal” as used herein may imply that the difference between the minimum auger speed M1/conveyor speed M3 and a maximum auger speed M2/conveyor speed M4 does not exceed an acceptable range value.

FIG. 4 illustrates an exemplary plot 402 wherein various speed values are marked on Y-axis and time instances are marked on X-axis. FIG. 4 illustrates exemplary speed curves C2, C3, and C4. The speed curve C4 is generated based on the speed signal received from the auger assembly 202 and/or the conveyor system 126. Alternatively, the speed curve C4 may be generated based on the input signal sent to the auger assembly 202 and/or the conveyor system 126 by the controller 228. The speed curve C4 as depicted herein is highly sinusoidal and indicates erratic operation of the material handling system 200. In such conditions, the controller 228 may apply the filter signal to dampen the speed of the auger assembly 202 and/or the conveyor system 126. The speed curve C3 is a dampened speed curve that is plotted after applying the filter signal.

Further, the controller 228 may generate the control signal C1 (see FIG. 3) after applying the filter signal so that the speed of the auger assembly 202 and/or the conveyor system 126 lies within the predetermined speed range R1, and the difference between the minimum auger speed M1 and the maximum auger speed M2 is minimal and/or the difference between a minimum conveyor speed M3 and a maximum conveyor speed M4 is minimal. Further, the speed curve C2 as illustrated in FIG. 4 is indicative of the speed of the auger assembly 202 and/or the conveyor system 126 after transmission of the control signal C1. It should be noted that the control signal C1 is determined such that the speed of the auger assembly 202 and/or the conveyor system 126 is close to a target speed T1.

Referring again to FIG. 3, in some examples, the alert notification A1 is displayed on the user interface 226. Based on the alert notification A1, the user may adjust the material feed sensor 204. For example, the user may adjust the material feed sensor 204 such that the pulse P1 (see FIG. 2) generated by the material feed sensor 204 is perpendicular to the paving material 104 (see FIG. 2). Further, the operator may also re-aim the material feed sensor 204 to target the material feed sensor 204 at live active paving material 104.

It should be noted that the controller 228 monitors a number of factors/conditions before transmitting the filter signal and/or the control signal C1 for adjusting the speed of the auger assembly 202 and/or the conveyor system 126. Only when the factors/conditions are met, the controller 228 may transmit the filter signal and/or the control signal C1 for adjusting the speed of the auger assembly 202 and/or the conveyor system 126. Details of each factor and its impact on the filter signal and/or the control signal C1 will now be explained in detail.

In an example, the controller 228 determines if the material handling system 200 is in the automated mode. Moreover, the controller 228 transmits the control signal C1 to the auger assembly 202 and/or the conveyor system 126 when the material handling system 200 is in the automated mode. In other words, only when the material handling system 200 is in the automated mode, the controller 228 transmits the filter signal and/or the control signal C1 to respectively dampen/adjust the speed of the auger assembly 202 and/or the conveyor system 126.

Further, the controller 228 determines if the screed assembly 210 is in the float mode. Furthermore, the controller 228 transmits the control signal C1 and/or the alert notification A1 when the screed assembly 210 is in the float mode. Alternatively, the controller 228 determines a mode of operation of the work machine 100. For example, the controller 228 determines if the work machine 100 is in a paving mode, a travel mode, or a maneuver mode. Furthermore, the controller 228 transmits the control signal C1 and/or the alert notification A1 when the work machine 100 is in the paving mode. Thus, only when the work machine 100 is in the paving mode and/or the float mode, the controller 228 transmits the filter signal to dampen the speed of the auger assembly 202 and/or the conveyor system 126, the control signal C1 to adjust the speed of the auger assembly 202 and/or the conveyor system 126, and/or the alert notification A1.

Further, the controller 228 receives the signal S3 indicative of the paving width from the screed width sensor 220 at different instances of time. Furthermore, the controller 228 transmits the control signal C1 and/or the alert notification A1 when the paving width at different instances of time is the same. Thus, only when the paving width remains unchanged for a given period of time, the controller 228 transmits the filter signal to dampen the speed of the auger assembly 202 and/or the conveyor system 126, the control signal C1 to adjust the speed of the auger assembly 202 and/or the conveyor system 126, and/or the alert notification A1. In other words, one or more parameters of the paving material 104 may have to be constant for a given period of time in for the controller 228 to transmit the filter signal, the control signal C1, and the alert notification A1.

Further, the controller 228 receives the signal S4 indicative of the paving depth PD1 (see FIG. 1) from the paving depth measuring device 222 at different instances of time. Furthermore, the controller 228 transmits the control signal C1 and/or the alert notification A1 if a change in the paving depth PD1 lies within an acceptable range. Further, only when the change in the paving depth PD1 lies within the acceptable range, the controller 228 may transmit the filter signal, the control signal C1, and/or the alert notification A1. Thus, only when the paving depth PD1 lies within the acceptable range, the controller 228 transmits the filter signal to dampen the speed of the auger assembly 202 and/or the conveyor system 126, the control signal C1 to adjust the speed of the auger assembly 202 and/or the conveyor system 126, and/or the alert notification A1. The acceptable range may be predetermined and configurable as per application parameters.

Further, the controller 228 determines if the work machine 100 is propelling in a forward direction D3 (see FIG. 1). Furthermore, the controller 228 transmits the control signal C1 and/or the alert notification A1 when the work machine 100 is propelling in the forward direction D3. Thus, only when the work machine 100 is propelling in the forward direction D3, the controller 228 transmits the filter signal to dampen the speed of the auger assembly 202 and/or the conveyor system 126, the control signal C1 to adjust the speed of the auger assembly 202 and/or the conveyor system 126, and/or the alert notification A1.

Further, the controller 228 also monitors a movement pattern of the work machine 100 for transmitting the control signal C1 and/or the alert notification A1. For this purpose, the controller 228 may receive signals corresponding to the speed of the work machine 100 from the machine speed sensor 116. In other examples, the controller 228 may monitor a steering system of the work machine 100 for monitoring the movement pattern of the work machine 100. Furthermore, the controller 228 transmits the filter signal, the control signal C1, and/or the alert notification A1 when the work machine 100 is moving along a straight path without taking any turns. However, if the work machine 100 takes a turn with more than a predetermined sharpness, the controller 228 may not transmit the filter signal, the control signal C1, and/or the alert notification A1. In an example, if the work machine 100 is traveling along a long arc (slight turn that is less than the predetermined sharpness), the controller 228 may transmit the filter signal, the control signal C1, and/or the alert notification A1. In some cases, the controller 228 may transmit the filter signal, the control signal C1, and/or the alert notification A1 even while the work machine 100 is taking a turn of more than the predetermined sharpness if other operations of the material handling system 200 are consistent.

It should be noted that the controller 228 takes into consideration each of the factors/conditions mentioned above, and only when each factor/condition is met, the controller 228 transmits the filter signal, the control signal C1, and/or the alert notification A1.

FIG. 5 illustrates a flowchart of a process 500 (or an algorithm) for handling material by the work machine 100. Referring to FIGS. 1 to 5, the process 500 may be executed by the controller 228. The process 500 may be stored as instructions within the memories 232 of the controller 228 and may be retrieved for execution by the processor 232. At a block 502, the process 500 starts or begins operation. At a block 504, the controller 228 determines if the work machine 100 is in the paving mode. If the work machine 100 is not in the paving mode, the process 500 moves to the block 502. However, if the work machine 100 is in the paving mode, the process 500 moves to a block 506.

At the block 506, the controller 228 determines if the screed assembly 210 is in the float mode. If the controller 228 determines that the screed assembly 210 is not in the float mode, the process 500 moves to the block 502. However, if the controller 228 determines that the screed assembly 210 is in the float mode, the process 500 moves to a block 508. At the block 508, the controller 228 determines if the work machine 100 is moving in the forward direction D3. If the work machine 100 is not moving in the forward direction D3, the process 500 moves to the block 502. However, if the controller 228 determines that the work machine 100 is moving in the forward direction D3, the process 500 moves to a block 510. At the block 510, the controller 228 determines if there is any change in the paving depth PD1. If the controller 228 determines that the change in the paving depth PD1 does not lie within the acceptable range, the process 500 moves to the block 502. However, if the controller 228 determines that the change in the paving depth PD1 lies within the acceptable range, the process 500 moves to a block 512. At the block 512, the controller 228 determines if the material handling system 200 is operating in the automated mode. If the controller 228 determines that the material handling system 200 is not operating in the automated mode, the process 500 moves to the block 502. However, if the controller 228 determines that the material handling system 200 is operating in the automated mode, the process 500 moves to a block 514.

At the block 514, the controller 228 determines if there is any change in the paving width. If the controller 228 determines that there has been a change in the paving width, the process 500 moves to the block 502. However, if the controller 228 determines that there has been no change in the paving width, the process 500 moves to a block 516. At the block 516, the controller 228 determines if a travel direction of the work machine 100 has been consistent over a period of time. For example, the controller 228 determines if the work machine 100 is taking a sharp turn. If the controller 228 determines that the work machine 100 is taking a sharp turn, the process 500 moves to the block 502. Further, the process 500 may move to the block 502 when the work machine 100 makes erratic steering motions or receives a large steering command over a short time (not shown).

However, if the controller 228 determines that the work machine 100 is not taking a sharp turn and moving along the straight or slightly curved path, the process 500 moves to a block 518. In some cases, the process 500 may move to the block 518 even when the work machine 100 is taking a slight turn, for example, when the work machine 100 is travelling along a long arc. At the block 518, the controller 228 determines if the speed of the auger assembly 202 and/or the conveyor system 126 is over damped.

If the controller 228 determines that the speed of the auger assembly 202 and/or the conveyor system 126 is not over damped, the process 500 moves to a block 520. However, if the controller 228 determines that the speed of the auger assembly 202 and/or the conveyor system 126 is over damped (or highly sinusoidal), the process 500 moves to a block 522. At the block 522, the controller 228 determines if the signal filtering of the auger assembly 202 and/or the conveyor system 126 has been enabled. If the controller 228 determines that the signal filtering of the auger assembly 202 and/or the conveyor system 126 is not enabled, the process 500 moves to the block 520. However, at the block 522, if the controller 228 determines the signal filtering of the auger assembly 202 and/or the conveyor system 126 has been enabled, the process 500 moves to a block 524. At the block 524, the controller 228 transmits the filter signal to dampen the speed of the auger assembly 202 and/or the conveyor system 126.

Further, from the block 524, the process 500 moves to a block 526. At the block 526, the controller 228 may transmit the alert notification A1 to the user of the work machine 100 to reposition the material feed sensor 204. Additionally, in some examples, the alert notification A1 may also notify the operator regarding the filter signal transmitted by the controller 228 to dampen the speed of the auger assembly 202 and/or the conveyor system 126.

From the block 526, the process 500 then moves to the block 520. At the block 520, the controller 228 determines if a height of the paving material 104 being directed by the auger assembly 202 and/or the conveyor system 126 is within a predefined height range (not shown). At the block 520, if the controller 228 determines that the height of the paving material 104 is within the predefined height range, the process moves to the block 502. However, at the block 520, if the controller 228 determines that the height of the paving material 104 is not within the predefined height range, the process moves to the block 528. At the block 528, the controller 228 determines if the speed of the auger assembly 202 and/or the conveyor system 126 is within the predetermined speed range R1.

Further, at the block 528, if the controller 228 determines that the speed of the auger assembly 202 and/or the conveyor system 126 is not within the predetermined speed range R1, the process 500 moves to a block 530. At the block 530, the controller 228 transmits the control signal C1 to the auger assembly 202 and/or the conveyor system 126 for adjusting the speed of the auger assembly 202 and/or the conveyor system 126 such that the speed of the auger assembly 202 and/or the conveyor system 126 lies within the predetermined speed range R1. Thus, at the block 530, the controller 228 may transmit the control signal C1 to achieve the target speed T1, which may lie within the predetermined speed range R1. From the block 530, the process 500 then returns to the block 502.

It may be desirable to perform one or more process steps shown in FIG. 5 in an order different from that depicted. Furthermore, various steps could be performed together. It should be noted that the controller 228 may execute the process 500 at regular intervals, or the controller 228 may execute the process 500 continuously.

INDUSTRIAL APPLICABILITY

The present disclosure relates to the material handling system 200 for the work machine 100. The material handling system 200 includes the controller 228 that sends the control signal C1 to the material handling system 200 based on the input signal S1 from the material feed sensor 204 that indicates if the paving material 104 is within a specified distance (such as, the distance D1) from the material feed sensor 204. The control signal C1 may increase or decrease the speed of the auger assembly 202 and/or conveyor system 126 accordingly. The material handling system 200 may reduce a probability of inconsistent operation of the auger assembly 202 and/or the conveyor system 126 by damping out the otherwise varying speed of the auger assembly 202 and/or the conveyor system 126, which may reduce a probability of generation of defects in the mat 128. Further, the control of the auger assembly 202 and/or the conveyor system 126 may reduce any drastic changes in the speed of the auger assembly 202 and/or the conveyor system 126 which may reduce a susceptibility to damage of the auger assembly 202 and/or the conveyor system 126.

Additionally, or alternatively, the controller 228 may also transmit the alert notification A1 to the user of the work machine 100 to reposition the material feed sensor 204. The alert notification A1 may notify the user that the material feed sensor 204 is not correctly positioned or may notify that the filter signal is being applied to dampen the speed of the auger assembly 202 and/or the conveyor system 126. The repositioning of the material feed sensor 204 may allow consistent operation of the auger assembly 202 and/or the conveyor system 126, which may in turn reduce the probability of generation of defects in the mat 128.

FIG. 6 illustrates a flowchart of a method 600 for handling material by the work machine 100. The work machine 100 includes the receptacle 124 for storing the paving material 104, the auger assembly 202, at least a portion of which is in communication with the receptacle 124, for directing the paving material 104 from the receptacle 124 for deposition on the work surface 102, the conveyor system 126 for conveying the paving material 104 from the receptacle 124 towards the auger assembly 202, and the material feed sensor 204 disposed at the outer end 206 of the auger assembly 202 and/or the conveyor system 126 to monitor the amount of the paving material 104 being directed towards the work surface 102.

At step 602, the controller 228 determines if the speed of the auger assembly 202 and/or the conveyor system 126 lies within the predetermined speed range R1. The controller 228 also monitors the auger assembly 202 and/or the conveyor system 126 to determine if the speed of the auger assembly 202 and/or the conveyor system 126 lies within the predetermined speed range R1.

At step 604, the controller 228 determines if the amount of the paving material 104 being directed towards the work surface 102 is outside of the predetermined amount range R2. The predetermined speed range R1 and the predetermined amount range R2 may be configured by the user via the user interface 226.

At step 606, if the speed of the auger assembly 202 and/or the conveyor system 126 is not within the predetermined speed range R1 and/or the amount of the paving material 104 being directed towards the work surface 102 is outside of the predetermined amount range R2, the controller 228 transmits the control signal C1 to the auger assembly 202 and/or the conveyor system 126 for adjusting the speed of the auger assembly 202 and/or the conveyor system 126 such that the speed of the auger assembly 202 and/or the conveyor system 126 lies within the predetermined speed range R1 and the alert notification A1 to the user of the work machine 100 to reposition the material feed sensor 204.

Further, the controller 228 also determines if the speed of the auger assembly 202 and/or the conveyor system 126 is over damped. Furthermore, the controller 228 transmits the filter signal to dampen the speed of the auger assembly 202 and/or the conveyor system 126 if the speed of the auger assembly 202 and/or the conveyor system 126 is over damped. Moreover, the alert notification A1 may also notify the user regarding the transmission of the filter signal to dampen the speed of the auger assembly 202 and/or the conveyor system 126.

The work machine 100 further includes the screed assembly 210 positioned downstream of the auger assembly 202 relative to the material movement direction D2. The screed assembly 210 spreads and compacts the paving material 104 into the mat 128 on the work surface 102. Further, the screed assembly 210 includes the one or more actuators 214.

Further, the controller 228 determines if the screed assembly 210 is in the float mode. Furthermore, the controller 228 transmits the control signal C1 and/or the alert notification A1 when the screed assembly 210 is in the float mode.

The work machine 100 further includes one or more screed width sensors 220 communicably coupled to the controller 228 to receive the signal S3 indicative of the paving width of the mat 128. Further, the controller 228 receives the signal S3 indicative of the paving width from the screed width sensor 220 at different instances of time. The controller 228 further transmits the control signal C1 and/or the alert notification A1 when the paving width at different instances of time is the same.

The work machine 100 further includes the paving depth measuring device 222 to determine the signal S4 indicative of the paving depth PD1 of the mat 128. Further, the controller 228 receives the signal S4 indicative of the paving depth PD1 from the paving depth measuring device 222 at different instances of time. The controller 228 transmits the control signal C1 and/or the alert notification A1 when the paving depth PD1 at different instances of time is the same.

Further, the controller 228 determines if the work machine 100 is in the paving mode. The controller 228 transmits the control signal C1 and/or the alert notification A1 when the work machine 100 is in the paving mode. Furthermore, the controller 228 determines if the work machine 100 is propelling in the forward direction D3. The controller 228 transmits the control signal C1 and/or the alert notification A1 when the work machine 100 is propelling in the forward direction D3.

It may be desirable to perform one or more of the steps shown in FIG. 6 in an order different from that depicted. Furthermore, various steps could be performed together.

Unless explicitly excluded, the use of the singular to describe a component, structure, or operation does not exclude the use of plural such components, structures, or operations or their equivalents. The use of the terms “a” and “an” and “the” and “at least one” or the term “one or more,” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The use of the term “at least one” followed by a list of one or more items (for example, “at least one of A and B” or one or more of A and B″) is to be construed to mean one item selected from the listed items (A or B) or any combination of two or more of the listed items (A and B; A, A and B; A, B and B), unless otherwise indicated herein or clearly contradicted by context. Similarly, as used herein, the word “or” refers to any possible permutation of a set of items. For example, the phrase “A, B, or C” refers to at least one of A, B, C, or any combination thereof, such as any of: A; B; C; A and B; A and C; B and C; A, B, and C; or multiple of any item such as A and A; B, B, and C; A, A, B, C, and C; etc.

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

Claims

1. A material handling system for a work machine, the material handling system comprising: a receptacle for storing paving material;an auger assembly, at least a portion of which is in communication with the receptacle, and configured to direct the paving material from the receptacle for deposition on a work surface;a conveyor system configured to convey the paving material from the receptacle towards the auger assembly;a material feed sensor disposed at an outer end of at least one of the auger assembly and the conveyor system, wherein the material feed sensor is configured to monitor an amount of the paving material being directed towards the work surface; anda controller communicably coupled to each of the auger assembly, the conveyor system, and the material feed sensor, wherein the controller is configured to: determine if a speed of at least one of the auger assembly and the conveyor system lies within a predetermined speed range;determine if the amount of the paving material being directed towards the work surface is outside of a predetermined amount range; andtransmit, if the speed of at least one of the auger assembly and the conveyor system is not within the predetermined speed range and/or the amount of the paving material being directed towards the work surface is outside of the predetermined amount range, at least one of: a control signal to at least one of the auger assembly and the conveyor system for adjusting the speed of at least one of the auger assembly and the conveyor system such that the speed of at least one of the auger assembly and the conveyor system lies within the predetermined speed range; andan alert notification to a user of the work machine to reposition the material feed sensor.

2. The material handling system of claim 1, wherein the controller is further configured to: determine if the speed of at least one of the auger assembly and the conveyor system is over damped; andtransmit a filter signal to dampen the speed of at least one of the auger assembly and the conveyor system if the speed of at least one of the auger assembly and the conveyor system is over damped.

3. The material handling system of claim 2, wherein the alert notification is further configured to notify the user regarding the transmission of the filter signal to dampen the speed of at least one of the auger assembly and the conveyor system.

4. The material handling system of claim 1, further including a screed assembly positioned downstream of the auger assembly relative to a material movement direction, wherein the screed assembly is configured to spread and compact the paving material into a mat on the work surface, and wherein the screed assembly includes at least one actuator, wherein the controller is further configured to: determine if the screed assembly is in a float mode; andtransmit at least one of the control signal and the alert notification when the screed assembly is in the float mode.

5. The material handling system of claim 4, further including at least one screed width sensor communicably coupled to the controller to receive a signal indicative of a paving width of the mat, wherein the controller is configured to: receive the signal indicative of the paving width from the screed width sensor at different instances of time; andtransmit at least one of the control signal and the alert notification when the paving width at different instances of time is the same.

6. The material handling system of claim 4, further including a paving depth measuring device configured to generate a signal indicative of a paving depth of the mat, and wherein the controller is further configured to: receive the signal indicative of the paving depth from the paving depth measuring device at different instances of time; andtransmit at least one of the control signal and the alert notification to the user when the paving depth at different instances of time is the same.

7. The material handling system of claim 1, wherein the controller is further configured to: determine if the work machine is in a paving mode; andtransmit at least one of the control signal and the alert notification when the work machine is in the paving mode.

8. The material handling system of claim 1, wherein the controller is further configured to: determine if the work machine is propelling in a forward direction; andtransmit at least one of the control signal and the alert notification when the work machine is propelling in the forward direction.

9. The material handling system of claim 1, further including a user interface, wherein the alert notification is displayed on the user interface.

10. The material handling system of claim 9, wherein the predetermined speed range and the predetermined amount range are configurable by the user via the user interface.

11. A method for handling material by a work machine, the work machine including a receptacle for storing paving material, an auger assembly, at least a portion of which is in communication with the receptacle, for directing the paving material from the receptacle for deposition on a work surface, a conveyor system configured to convey the paving material from the receptacle towards the auger assembly, and a material feed sensor disposed at an outer end of at least one of the auger assembly, and the conveyor system and configured to monitor an amount of the paving material being directed towards the work surface, the method comprising: determining, by a controller, if a speed of at least one of the auger assembly and the conveyor system lies within a predetermined speed range;determining, by the controller, if the amount of the paving material being directed towards the work surface is outside of a predetermined amount range; andtransmitting, by the controller, if the speed of at least one of the auger assembly and the conveyor system is not within the predetermined speed range and/or the amount of the paving material being directed towards the work surface is outside of the predetermined amount range, at least one of: a control signal to at least one of the auger assembly and the conveyor system for adjusting the speed of at least one of the auger assembly and the conveyor system such that the speed of at least one of the auger assembly and the conveyor system lies within the predetermined speed range; andan alert notification to a user of the work machine to reposition the material feed sensor.

12. The method of claim 11, further comprising: determining, by the controller, if the speed of at least one of the auger assembly and the conveyor system is over damped; andtransmitting, by the controller, a filter signal to dampen the speed of at least one of the auger assembly and the conveyor system if the speed of at least one of the auger assembly and the conveyor system is over damped.

13. The method of claim 12, wherein the alert notification is further configured to notify the user regarding the transmission of the filter signal to dampen the speed of at least one of the auger assembly and the conveyor system.

14. The method of claim 11, further comprising monitoring, by the controller, at least one of the auger assembly and the conveyor system to determine if the speed of at least one of the auger assembly and the conveyor system lies within the predetermined speed range.

15. The method of claim 11, wherein the work machine further includes a screed assembly positioned downstream of the auger assembly relative to a material movement direction, wherein the screed assembly is configured to spread and compact the paving material into a mat on the work surface, and wherein the screed assembly includes at least one actuator.

16. The method of claim 15, wherein the work machine further includes at least one screed actuator sensor associated with the actuator of the screed assembly, wherein the screed actuator sensor is communicably coupled to the controller to receive a signal when the screed assembly is in a float mode, and wherein the method further includes: determining, by the controller, if the screed assembly is in the float mode; andtransmitting, by the controller, at least one of the control signal and the alert notification when the screed assembly is in the float mode.

17. The method of claim 15, wherein the work machine further includes at least one screed width sensor communicably coupled to the controller to receive a signal indicative of a paving width of the mat, and wherein the method further includes: receiving, by the controller, the signal indicative of the paving width from the screed width sensor at different instances of time; andtransmitting, by the controller, at least one of the control signal and the alert notification when the paving width at different instances of time is the same.

18. The method of claim 15, wherein the work machine further includes a paving depth measuring device configured to generate a signal indicative of a paving depth of the mat, and wherein the method further includes: receiving, by the controller, the signal indicative of the paving depth from the paving depth measuring device at different instances of time; andtransmitting, by the controller, at least one of the control signal and the alert notification when the paving depth at different instances of time is the same.

19. The method of claim 11, wherein the method further includes: determining, by the controller, if the work machine is in a paving mode; andtransmitting, by the controller, at least one of the control signal and the alert notification when the work machine is in the paving mode.

20. The method of claim 11, wherein the method further includes: determining, by the controller, if the work machine is propelling in a forward direction; andtransmitting, by the controller, at least one of the control signal and the alert notification when the work machine is propelling in the forward direction.