MACHINE CONSUMABLE REPLENISHMENT SYSTEM
A system for replenishing a paving machine includes a position sensor which generates a position signal indicating a position of the paving. The system also includes a consumable level sensor which generates a consumable level signal indicating a level of the consumable. There is also a controller which determines a threshold level for the consumable. The controller receives the position signal as well as the consumable level signal and determines if the consumable level is below the threshold. A signal is sent from the controller to a refilling machine if the consumable level is below the threshold, and the controller prepares a travel path for the refilling machine such that the refilling machine travels outside of a path traveled by the paving machine.
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The present disclosure relates generally to a system for replenishing a consumable on a machine, and more particularly to a system which tracks worksite variables to determine when to replenish the consumable.
BACKGROUNDThe various machinery operated at worksites generally use up one or more consumables to perform their designated task(s). Some consumables, such as battery charge for an electric machine, are general use consumables and are consumed constantly while the machine is operational. Other consumables, such as water sprayed on a compactor drum, are task specific and are not consumed unless the machine is performing that specific task. These machines generally have a supply of the consumables stored onboard the machine in a tank, battery, or other storage device. This allows the machine to run for an extended period of time prior to the consumable running out and needing replenishing.
Ideally, the amount of consumable stored onboard the machine allows the machine to perform its designated task(s) or run for an entire shift prior to needing replenishment of the consumable. This allows the machine to have its consumable(s) replenished while the machine would otherwise be idle. However, due to a variety of factors, such as worksite conditions, machine damage, workload, or others, it is not uncommon for one or more consumables to be depleted prior to finding such a time. In such cases, the machine generally ceases the current task, replenishes the consumable, and then resumes the task. These stoppages reduce the uptime of the machine and may also substantially reduce the efficiency of the worksite.
U.S. Pat. No. 9,463,483B2 describes a mobile fluid delivery machine for delivering fluid to a worksite, where it may subsequently spray the fluid in predetermined areas to control dust conditions. Accordingly, the fluid delivery truck includes a spray head which sprays fluid from a fluid storage tank onto the worksite. The fluid delivery truck further includes a location device for determining its location, as well as a communication device for receiving fluid delivery mission instructions which identify a sequence of path segments on a site and corresponding fluid delivery allocation information for the path segments. The fluid delivery truck further includes a processor which determines a fluid delivery rate for the path segments and is configured to cause a display device to display that information. The '483 patent represents one possible approach for refilling fluids on a machine, but additional future designs might present other choices.
SUMMARYIn an aspect of the present disclosure, there is system for refilling consumables on a construction machine. The system includes a first and second consumable level sensor, both associated with the construction machine for generating a first and second consumable level signal. The first and second consumable level signals are indicative of a first and second consumable level of a first and second consumable on the construction machine. The system further includes a controller that determines a run time required to complete a task as well as receives the first and second consumable level signals from the first and second consumable level sensors. The controller also determines the first and second consumable levels based on the first and second consumable level signals and triggers a task to refill one of the consumables if one of the consumable levels is less than what is required to complete the task within the run time.
In another aspect of the present disclosure, there is a system for refilling a paving train machine. The system includes a position sensor associated with the paving train machine for generating a position signal indicative of a position of the paving train machine as well as a first consumable level sensor associated with the paving train machine for generating a first consumable level signal for a first consumable on the paving train machine. The system further includes a controller which receives the position signal from the position sensor and determines a position of the paving train machine based on the position signal. The controller also determines a threshold level for the first consumable, receives the first consumable level signal from the first consumable level sensor, and determines the first consumable level based on the first consumable level signal. The controller further sends a signal to a refilling machine to deliver consumable to the paving train machine if the first consumable level is below the threshold first consumable level, and prepares a travel path for the refilling machine to deliver the consumable such that the refilling machine travels outside of a path traveled by the paving train machine.
In yet another aspect of the present disclosure, there is a method of replenishing a consumable of a paving train machine using a refilling machine. The method includes mapping a traveled location of the paving train machine while operational. The method also includes determining a consumable depletion time based on the amount of consumable remaining and the rate of consumable depletion. The method further includes sending a signal to the refilling machine to deliver consumable to the paving train machine prior to the consumable being depleted and directing the refilling machine to travel to and then alongside the paving train machine such that the refilling machine avoids the traveled location.
Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings.
Referring to
The primary machine 100 includes a first consumable storage device 108, a second consumable storage device 110, and a work implement 111. The first and second consumable storage devices, 108 and 110, each carry a consumable required for some operation of the primary machine 100. The work implement 111 is used by the primary machine 100 to complete one or more task(s).
The refilling machine 102 includes a reservoir 112 as well as a conduit 114. The reservoir 112 stores the consumable for replenishing the primary machine 100. The conduit 114 is attached to the reservoir 112 and facilitates the movement of the consumable from the reservoir 112 to the consumable storage devices, 108 and/or 110.
The consumable storage devices, 108 and 110, may be one or more of a tank, battery, or other device capable of storing a consumable, such as a liquid. The reservoir 112 may be similar to the consumable storage devices, 108 and 110, however, may also be a consumable generation device such as a generator. The consumables may include one or more of a fuel, a battery charge, diesel emission fluid, water, and the like and combinations thereof.
Referring to
The primary machine 100 is a machine that performs one or more work tasks at a worksite and consumes one or more onboard consumable(s) to do so. The ancillary machine 202 is a machine located or working at the same worksite as the primary machine 100. Although not required, the ancillary machine 202 may be suited to take over one or more tasks from the primary machine 100, such that task(s) may be completed by the ancillary machine 202 if the primary machine 100 has downtime, such as traveling to and from a refilling location 204.
The refilling machine 102 is a machine that stores or generates an amount of consumable at the worksite. The refilling machine 102 interfaces with one or more of the primary machine 100, ancillary machine 202, and/or refilling station 204 to replenish and/or take consumable from them. The mobility of the refilling machine 102 allows the primary machine 100 and/or ancillary machine 202 to continue performing tasks while a consumable is brought to their location. The mobility of the refilling machine 102 also allows the primary machine 100 and/or ancillary machine 202 to be refilled while performing the task(s).
The refilling station 204, like the refilling machine 102, stores or generates an amount of consumable at the worksite. The refilling station 204 is also capable of interfacing with the primary machine 100, ancillary machine 202, and/or the refilling machine 102. Unlike the refilling machine 102, the refilling station 204 is immobile, such that a machine needing to take consumable from or provide consumable to the refilling station 204 must travel to the refilling station 204 in order to do so. The refilling station 204 may be any number of simple or complex devices, for example, the refilling station 204 may be a liquid or gas storage system, electrical generation and/or storage system, or other system.
The back office 206 includes one or more devices off-board the primary machine 100 that are capable of receiving, generating, storing, processing, and/or providing signals that may be used to monitor and/or control operations of the various machines and/or systems located at the worksite, such as a computer. For example, the back office 206 may provide instructions to the primary machine 100 to cause the primary machine 100 to begin, cease, or change tasks. The back office may also monitor the task(s) and provide task progress to the primary machine 100, such as percentage completed, run time on the task, and run time remaining. Additionally, the back office 206 may provide instructions to ancillary machine 202 and/or refilling machine 102 to cause ancillary machine 202 and/or refilling machine 102 to perform tasks.
The network 208 allows the portions of the system 200 to wirelessly communicate with one or more of the other portions. There may be more than one network 208 within the system 200 such that the systems have access to multiple methods of communication, decrease the number of systems on the same network, and/or increase the reliability or security of the communications. For example, there may be longer-range networks that may support cellular communication, variable-range networks such as Wi-Fi communication, as well as shorter-range networks that may support Bluetooth communication. The network 208 may be integrated within each of the pieces of the system 200.
Due to various worksite constraints or system availability, the system 200 described above may lack one or more of the structures. For example, there system 200 may be missing the ancillary machine 202. In another example, the system 200 may not include a network 208, with the various pieces of the system 200 being able to communicate directly with one another. Further, one of the refilling location 204 or refilling machine 102 may not be available at the worksite, such that determining replenishing of the consumable(s) needs to account for traveling to and from the refilling location 204 or the travel time for the refilling machine 102 to arrive.
Referring to
The first and second consumable sensors, 302 and 304, are in communication with their respective first and second consumable storage devices, 108 and 110. The consumable sensors, 302 and 304, include one or more devices that are capable of receiving, generating, storing, processing, and/or providing signals. The consumable sensors, 302 and 304, periodically send corresponding first and second consumable level signals, 316 and 318, to the controller 310, the consumable level signals, 316 and 318, indicative of the level of consumable in the first and second consumable storage devices, 108 and 110.
Depending on the consumables onboard the primary machine 100, the consumable sensors, 302 and 304, may be any number of various sensor types. For example, if a consumable is battery charge, one of the consumable sensors, 302 and 304, may be one or more current, resistive, and/or voltage sensors. If a consumable is fuel, DEF, water, or other fluid stored in a tank, one of the sensors, 302 and 304, may be a float sensor, capacitive sensor, and/or ultrasonic sensor.
The position sensor 304 includes one or more devices that are capable of receiving, generating, storing, processing, and/or providing signals that may be used to determine one or more of a location, a velocity, and/or a movement of the primary machine 100. For example, the position sensor 306 may generate location data 320 and send it to the controller 310 to be used to determine the current location and speed of the primary machine 100, the location data 320 used by the controller 310 to generate a path of the primary machine 100 as it travels around the worksite.
The work sensor 308 includes one or more devices that are capable of generating, storing, processing and/or providing signals that may be used to determine the status of a surface. The work sensor 308 sends a work signal 322 to the controller 310 indicative of the status of the worked 106 and/or unworked 104 surface. For example, the work sensor 308 may be a temperature sensor which generates temperature data that may be used to determine the temperature of a worked surface 106 and/or unworked 104 surface. The work sensor 306 may also or instead be a pressure sensor and/or motor input/output sensor that may be used to determine a compactness level of the worked surface 106 and/or unworked surface 104.
The controller 310 receives, stores, and processes information from the sensor(s) and other worksite machines onboard the primary machine 100. The controller 310 also controls and/or monitors operations of the primary machine 100. For example, the controller 310 may control and/or monitor the operations of the primary machine 100 based on signals from the consumable sensors, 302 and 304, position sensor 306, work sensor 308, and/or from the back office 206. For example, the controller 310 may process information from the back office 206 to work an area and may also process and cause communication device 312 to send collected and processed data to the back office 206, ancillary machine 202, refilling machine 102, and/or refilling station 204.
The communication device 312 may be one or more devices that enable the primary machine 100 to communicate through the network 208 with one or more of the other portions of the system 200 described in
The output device 314 may be one or more devices that generate an output from the primary machine 100. The output device 314 may be an operator alert device. Example output device 314 may include a monitor, wireless device, horn, light, and others. Controller 310 uses output device 314 to relay information, such as task information, consumable levels, and consumable depletion rates, as well as signaling warnings or thresholds. For example, the output device 314 may be a horn and when a consumable level is below a threshold, or if there is a difference between task run time remaining and consumable depletion time, the horn may sound.
Although illustrated as being located on the primary machine 100, the output device 314 may instead or also be located remotely from the primary machine 100, including but not limited to on the ancillary machine 202, refilling machine 102, refilling station 204, and/or back office 206. For example, in remote or autonomous operation, there may be no need for an output device 314 to be located on the primary machine 100, rather the output device 314 is associated with the back office 206. Accordingly, information and warnings relayed by the output device 314 may be received away from the primary machine 100.
Referring to
As shown, there is a primary machine 100, an ancillary machine 202, and a refilling machine 102. The ancillary machine 202 is shown working a prepped area 402, creating an unworked area 104. The primary machine 100 is shown working the unworked area 104, creating a worked area 106 and a traveled path 404. Refilling machine 102 is shown travelling outside of the areas being worked and is following a directed path 406 to the other side of the areas being worked, directed path 406 crossing the traveled path 404. A stable area 408, is shown behind the worked area 106.
The primary machine 100 is illustrated as an asphalt compactor, and is traveling behind the ancillary machine 202, illustrated as an asphalt paver. The ancillary machine 202 is working on the prepped surface 404, depositing asphalt and creating the unworked surface 104, illustrated as an uncompacted roadway. The primary machine 100 is following behind the ancillary machine 202, working the unworked surface 104 by compacting it and creating a worked surface 106, illustrated as a compacted roadway.
The primary machine 100 is also shown mapping the traveled path 404. The traveled path 404 includes information such as a positional, time, and/or surface data. Here, the primary machine 100 is mapping the traveled path 404 using time compacted and sensed asphalt mat temperature. That information is used to determine when portions of the traveled path 404 are suitable for machine travel, such that they may be marked as a stable area 408. Here, the worked area 106 is initially too hot and soft for machine travel, however as it cools, it becomes the stable area 408. The traveled path 404 is updated periodically as the primary machine continues working to add additional traveled path 404. In some embodiments, the traveled path 404 may be updated to also remove portions of the traveled path 404 which have transitioned from worked area 106 to stable area 408.
Here, the primary machine 100 has called for the refilling machine 102 to replenish a consumable. Accordingly, the refilling machine 102 has been directed towards the primary machine 100, however needs to cross the traveled path 404. The primary machine 100 has accounted for the traveled path 404 and has determined where the stable area 408 is and has created the directed path 406 for the refilling machine 102 that crosses the traveled path 404 within the stable area 408.
Although illustrated as operator-driven machines, in a more connected worksite 400 the primary machine 100, ancillary machine 202, and/or refilling machine 102 may be replaced with autonomous machines. Accordingly, the information collected by each of the machines may be shared with the back office 206 or may be delivered directly to the other machines. Such a solution may keep all machines and any remote operators/observers aware of the status of the machine(s) and task(s) at the worksite. Accordingly, such a worksite may need minimal, if any, operator intervention.
Referring to
The controller 310 also receives information from one or more of the other machines at the worksite, such as ancillary machine 202, refilling machine 102, and refilling station 204. Information received from the other machines includes and/or allows the primary machine 100 to determine the location, speed, work surface data, consumable levels, task data, and other information about and/or gathered by the other machines. The controller 310 receives and stores each of the received signals, statuses, and information.
At step 504, the controller 310 determines the traveled path 404. During this step, the primary machine 100 uses the signals from the position sensor 306 to determine the current location of the primary machine 100. The signals from the position sensor 306 are also stored by the controller 310 to create the traveled path 404 of the primary machine 100 over time. The traveled path 404 may include positional and time data, as well as work surface characteristic data as described below.
While mapping the traveled path 404, the controller 310 receives the work signal 322 from the work sensor 308 and determines various characteristics about the work surface along the traveled path 404. For example, the work signal 322 may be used to determine characteristics such as the temperature, compaction level, and wetness, among others. This information is sent to the controller 310 which tracks and determines if the work surface is suitable for machine traffic, as well as estimating if or when the surface may be ready for machine traffic. Once the traveled path 404 is determined to be suitable for machine traffic, that portion of the traveled location 516 is marked differently, unmapped, or otherwise removed from the stored traveled location 516.
For example, during the asphalt compacting process illustrated in
At step 506, the controller 310 determines a threshold level for the consumable(s). The primary machine 100 uses the signals from the consumable level sensors, 302 and 304, position sensor 306, and work sensor 308 to determine the usage rate of the consumable. The controller 310 compares the usage rate of the consumable to the signals received from the consumable sensors, 302 and 304, which indicate the level of the consumable(s) onboard the primary machine 100. This allows the primary machine 100 to determine when the various consumables will be depleted. The controller 310 also receives from the back office 206 the work plan 324 to determine a run time to complete the current task(s). Additionally, the controller 310 or back office 206 may monitor the status(es) of any ancillary machine(s) 202 at the worksite capable of taking over the task(s), as well as distances from any refilling machine(s) 102 and/or refilling station(s) 204.
Based on the consumable depletion time(s), run time(s), and status(es), the controller 310 creates or updates a threshold level for each of the consumables. The threshold level is the amount of consumable necessary to ensure a replenishment of the consumable prior to the consumable being depleted and includes reserving any necessary consumable for travelling to or from a refilling machine 102 and/or refilling station 204 or having refilling machine 102 travel to primary machine 100. The threshold level may include a buffer amount to account for any potentially encountered delays or issues.
At step 508, the controller 310 triggers a task to replenish one or more consumables. Here the controller 310 determines that one or more consumables are at or below the threshold level. Further, the controller also determines that there are no ancillary machine(s) 202 available to take over the task(s), such that the primary machine 100 may run below the threshold amount. Once that information is determined, the primary machine 100 triggers the task to refill the one or more consumables.
The task to refill the consumables includes using the traveled path 404, work plan 324, and location of the primary machine 100 as well as the location of the refilling machine 102 and/or refilling station 104 to create the directed path 406 between the primary machine 100 and the refilling machine 102 and/or refilling station. The directed path 406 avoids areas along the traveled path 404 which are not marked as the stable area 408, and may also include avoiding specific road surfaces, hazards, and/or other machines, among others. The directed path 406 may be continuously updated by the controller 310 as additional information is received by the controller 310.
At step 510, the controller 310 guides the refilling machine 102 to the primary machine 100 using the path and replenishing the consumable(s). Depending on the worksite circumstances, this step may instead be guiding the primary machine 100 to a refilling machine 102 or refilling station 204 or guiding the ancillary machine 202 to the primary machine 100. To guide the primary machine 100 or another machine, the controller 310 sends the directed path 406 to the machine to be moved and further sends information to and receives information from the other machine to update the directed path 406 as the machine travels.
Although the information gathered and received by the primary machine 100, ancillary machine 202, refilling machine 102, and refilling station 204 is described as first passing through the back office 206, some or all of the information may be passed directly from each of these machines to one another, as each of the machines may be able to perform the functions, calculations, and/or instructions independently.
Although described as a compactor, the primary machine 100 may be any number of machines, and the surfaces may be different depending on the machine working. One example is that the primary machine 100 is a cold planer, the unworked area being a paved surface and the worked surface being a milled surface. Another example is that the primary machine 100 is a rotary mixer, and the unworked surface is an unmixed bed, the worked surface being a mixed uncompacted bed. Further, other examples may exist within the agricultural space, for prepping rail beds, general construction, and the like.
INDUSTRIAL APPLICABILITYAs described in the paving example above, the present disclosure may be used at a variety of different worksites to refill machines without delaying task completion times. However, the present disclosure is especially effective when on a worksite where the tasks being completed create areas that may be temporarily unsuitable for machine traffic. The present disclosure allows the ability for a machine to call or schedule a replenishment of a consumable and creates a path for the machine and/or a machine carrying a consumable to travel on.
Accordingly, machines using the present invention may see a decrease in task downtime, with machines spending more time working their assigned tasks and less time determining and scheduling consumable replenishment. Additionally, updated travel locations may allow for more accurate arrival times by the construction machine and/or refilling machine, such that there is less error and more efficient scheduling of the various machines on-site. Further, unnecessary damage to work areas and/or machines may be lessened or avoided, reducing the amount of time spent repairing work which was already completed.
Further, the present disclosure may be particularly useful in the autonomous or auto-driving space, such that the machines are able to monitor and keep the other machines working with minimal to no downtime.
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 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 system for refilling consumables on a construction machine, comprising:
- a first consumable level sensor associated with the construction machine for generating a first consumable level signal indicative of a first consumable level of a first consumable on the construction machine;
- a second consumable level sensor associated with the construction machine for generating a second consumable level signal indicative of a second consumable level of a second consumable on the construction machine;
- a controller configured to: determine a run time required to complete a task; receive the first consumable level signal from the first consumable level sensor and the second consumable level signal from the second consumable level sensor; determine the first consumable level based on the first consumable level signal and the second consumable level based on the second consumable level signal; and trigger a task to refill one of the consumables if one of the consumable levels is less than what is required to complete the task within the run time.
2. The system of claim 1, wherein determining the consumable levels includes determining the available consumable remaining as well as one of:
- determining the rate of consumption of the consumable; and
- determining a depletion time.
3. The system of claim 2, wherein the task to refill one of the consumables includes locating and traveling to a location to refill, and the step of determining the consumable levels further includes estimating and reserving the amount of consumable necessary for the construction machine to travel to the location.
4. The system of claim 2, wherein the task to refill one of the consumables includes locating and directing a refilling machine to travel to and refill the construction machine, and the step of determining the consumable levels further includes estimating and reserving the amount of consumable necessary for the refilling machine to deliver the consumable to the construction machine before the depletion time.
5. The system of claim 2, further including an operator alert device, wherein the controller is further configured to notify a machine operator using the operator alert device of the difference between the run time and the depletion time.
6. The system of claim 2, wherein the construction machine is a compactor and wherein determining the rate of consumption of the consumable includes takes into account the compactor speed and asphalt mat temperature.
7. The system of claim 1, wherein the controller is further configured to determine the availability of another construction machine to take over the task from the construction machine.
8. The system of claim 1, wherein the first consumable is chosen from the group consisting of battery charge and diesel fuel, and the second consumable is chosen from the group consisting of diesel exhaust fluid and water.
9. A system for refilling a paving machine, comprising:
- a position sensor associated with the paving machine for generating a position signal indicative of a position of the paving machine;
- a first consumable level sensor associated with the paving machine for generating a first consumable level signal for a first consumable on the paving machine; and
- a controller configured to: receive the position signal from the position sensor; determine a position of the paving machine based on the position signal; determine a threshold level for the first consumable; receive the first consumable level signal from the first consumable level sensor; determine the first consumable level based on the first consumable level signal; send a signal to a refilling machine to deliver consumable to the paving machine if the first consumable level is below the threshold first consumable level; and preparing a travel path for the refilling machine to deliver the consumable such that the refilling machine travels outside of a path traveled by the paving machine.
10. The system of claim 9, further including:
- a second consumable level sensor associated with the paving machine for generating a second consumable level signal indicative of a consumable level of a second consumable on the paving machine; and
- wherein the controller is further configured to: determine a threshold level for the second consumable; receive the second consumable level signal from the second consumable level sensor; determine the second consumable level based on the second consumable level signal; and send a signal to a refilling machine if the second consumable level is below the threshold second consumable level.
11. The system of claim 10, wherein the first consumable is fuel and the second consumable is water.
12. The system of claim 10, wherein the first consumable is battery charge and the second consumable is water.
13. The system of claim 9, wherein determining the threshold first consumable level includes one or more of:
- determining a speed of the paving machine; and
- determining an amount of area ready to be worked.
14. The system of claim 13, wherein the paving machine is a compactor and determining the threshold first consumable level further includes determining the asphalt mat temperature.
15. The system of claim 14, wherein determining the threshold first consumable level further includes determining the availability of another compactor to swap working positions with.
16. The system of claim 9, wherein the controller is further configured to determine a path taken while operating, the controller directing the refilling machine to travel around the path.
17. A method of replenishing a consumable level of a paving machine using a refilling machine, comprising;
- mapping a traveled location of the paving machine while operational;
- determining a consumable depletion time based on one of: the amount of consumable remaining; and the rate of consumable depletion;
- sending a signal to the refilling machine to deliver consumable to the paving machine prior to the consumable being depleted; and
- directing the refilling machine to travel to and then alongside the paving machine such that the refilling machine avoids the traveled location.
18. The system of claim 17, wherein determining the consumable depletion time further includes estimating a future demand of the consumable.
19. The system of claim 18, wherein the paving machine is a compactor and estimating the consumable depletion time further includes one or more of:
- estimating the unworked asphalt mat temperature;
- estimating the compactor compacting speed.
20. The system of claim 19, further including the step of estimating the worked asphalt mat temperature at previously traveled locations and unmapping them if the asphalt mat temperature is below a temperature threshold.
Type: Application
Filed: Apr 29, 2025
Publication Date: Oct 29, 2026
Applicant: Caterpillar Paving Products Inc. (Brooklyn Park, MN)
Inventors: Nathaniel Doy (Clayton, NC), Matthew Thomas Hanson (St Louis Park, MN), Paul Russell Friend (Morton, IL), Nicholas Aaron Greene (Elk River, MN)
Application Number: 19/192,519