MIXER DRUM LOAD DETECTION SYSTEM

A load measurement system for a mixer comprising a mixing drum configured to contain and mix concrete, a cradle adjacent to the mixing drum and configured to receive the mixing drum, and a load measurement device adjacent to the cradle and configured to determine the changes to a material property of the cradle due to the force exerted on the cradle by the load in the mixing drum. The load measurement system determines the amount of the load of concrete in the mixing drum based on the measured change to the material property of the cradle, which may include one or more of a material deformation, displacement, stress, strain, or the vibration of the cradle.

TECHNICAL FIELD

The present invention generally relates to concrete mixers and determining the amount of concrete contained in the mixer. More specifically, the present invention relates to indirectly determining the amount of concrete in a mixer based on measurements pertaining to a change to a material property of a cradle receiving the mixing drum of the mixer.

BACKGROUND

Concrete batch plants are used in the preparation of concrete. Batch plants may be stationary in nature or portable in nature. Dry concrete ingredients including concrete, aggregates, and admixtures for modifying the properties of the concrete, are measured and apportioned by the batch plants. The dry concrete ingredients and water are loaded into the mixing drum of the batch plant or other stationary or portable mixer, which is rotated to mix the ingredients to form concrete. If the concrete is to be transported, the concrete may be loaded into the mixing drum of a delivery truck and may be mixed therein or it may have been mixed in advance.

Hines et al. taught that the amount of admixture to be dosed into a mixer drum of a delivery truck returning from delivery can be calculated based on the remaining load size and temperature of the concrete (see U.S. Pat. No. 6,042,258) and that admixture dosing could be done on an automated basis (see U.S. Pat. No. 6,042,259).

Some in the industry believe that prior art methods for calculating the concrete load remaining in the mixer drum after delivery are neither sufficiently accurate nor practically convenient. See U.S. Pat No. 10,363,684. For example, it is known to weigh a delivery truck on a weight scale before and after delivery of concrete (see, e.g., U.S. Pat. Nos. 5,752,768; 6,123,444; 8,020,431; and GB 2392502), but weight can vary due to imprecision of the scale and various other factors, such as fluctuation of fuel tank and other fluid tank levels. It is also known to estimate concrete discharged from the drum by counting mixing drum rotations required to discharge a known volume of concrete (see, e.g., U.S. Pat. Nos. 5,752,768; 8,020,431; 8,118,473). It also known to calculate the concrete load size by using sensors to determine the load size of concrete by sensing the number of mixing drum rotations to discharge the concrete and the rate of discharge. See U.S. Pat No. 10,363,684.

The present inventors believe there is a need to be able to determine the amount of concrete in mixing drums at all times, not just after delivery. For instance, knowing the concrete load at all times allows remote users to determine whether a user is cleaning out the concrete mixer overnight or between batches.

The present inventors also believe there is a need to determine the yards of concrete in the drum, uniform drum buildup, and lopsided drum buildup at all times. Having ready access to these calculations could offer improved quality of concrete, as well as improved equipment care and maintenance.

As such, a need exists in the industry for a load measurement system operable to indirectly calculate (rather than directly weigh the load in the drum) the amount of concrete currently in a concrete mixer.

SUMMARY

In one embodiment, the invention comprises a system for determining the amount of concrete currently in a concrete mixing drum based on measurements pertaining to the strain and/or displacement, of a cradle receiving a drum of the concrete mixer.

In another embodiment, the invention comprises a method for indirectly determining the amount of concrete currently in a concrete mixer based on measurements pertaining to the strain and/or displacement of a cradle receiving a drum of the concrete mixer.

In a further embodiment, the method comprises a method for managing a mixing drum that includes sending alerts based on measurements pertaining to the strain and/or displacement of a cradle receiving a drum of the concrete mixer.

DETAILED DESCRIPTION

Embodiments of the present invention are further described in detail below with reference to the accompanying drawings and embodiments. The following examples are intended to illustrate the invention, but are not intended to limit the scope of the invention.

“Concrete” as used herein will be understood to refer to materials including a cement binder, water, aggregates (such as sand, crushed gravel or stones), and/or admixtures (such as plasticizers, stabilizers, water-reducing agents, set retarders, set accelerators, air entrainers, air detrainers, strength enhancers, pigments, colorants, fibers for plastic shrinkage control or structural reinforcement, and the like).

“Mixing drum” as used herein will be understood to refer to a drum that is mounted for rotation on a mixer, such as may be found in a mixing plant or on a delivery vehicle. A mixing drum typically has at least one mixing blade attached to the inner surface so that it rotates along with the mixing drum and serves to mix the concrete. The mixing drum can be used to mix concrete as well as for other mixtures, such as asphalt and the like. Examples of such mixing drums may include drum mixers, tilt mixers, non-tilting mixers, reversing drum mixers, batch plants, mixing plants, and the like. The mixing drum may be mounted on a stationary or portable mixer. A portable mixing drum may be mounted a delivery vehicle, trailer, skid, portable wheeled frame, portable stationary-legged frame, or the like.

“Delivery vehicle” as used herein means any vehicle used in the construction industry that can be modified or constructed to incorporate an operable mixing drum such that the delivery vehicle can serve as a mobile mixing device. As used herein construction vehicles can include, but are not limited to, flatbed trucks, dump trucks, cement mixer trucks, or the like.

Referring toFIGS.1A and1B, a perspective and a side view of an embodiment of a load measurement system is illustrated. A load measurement system100for a mixer comprises a mixing drum110configured to contain and mix concrete, a cradle120adjacent to the mixing drum110and configured to receive the mixing drum110, and a load measurement device130adjacent to the cradle120. The load measurement system100is configured to determine the amount of a load of concrete in the mixing drum110by measuring the changes to the material properties of the cradle120due to the forces exerted on the cradle120by the load within the mixing drum110. The measured changes to the material properties of the cradle120may include one or more of material deformation, displacement, stress, strain, or vibration.

The cradle120is substantially U-shaped and operable to receive the drum110. The cradle120may be attached to a stationary, fixed stand, or portable stand such as may be used by a delivery vehicle or other portable frame.

The cradle120comprises a cradle pivot122and rollers124. The cradle pivot122attaches to the fixed stand or trailer stand. The cradle pivot122stabilizes the cradle120while a tilting cylinder140, also connected at one end to the fixed stand or trailer stand, employs hydraulic power to lift or tilt the cradle120about the cradle pivot122. The rollers124are located between the cradle120and the drum110. The rollers124facilitate the rotation of the drum110.

The drum110is adjacent to the rollers124and is received within the U-shaped cradle120. The drum110further comprises a drum ring112that is welded to the outside of the drum110and acts as an outer layer. The drum ring112is in direct contact with the rollers124. Motors are in direct contact with the drum ring112, thereby enabling the rollers124to facilitate the rotation of the drum110. In one embodiment, motors are placed at the ten o'clock and two o'clock positions of the drum ring112when viewing the drum110from the front. The drum110is operable to receive a concrete mix or similar mix. When the drum110rotates, it mixes the concrete or similar mix within the drum110.

Pinch rollers150are located at the base and along the arms of the U-shaped cradle120to receive the drum ring112and facilitate smooth rotation of the drum110. With respect to tilt mixers, pinch rollers150are needed to stabilize the load measurement system100because the cradle120is in a tilted state. The pinch rollers150may be positioned anterior (along the front side) or posterior (along the back side) to the drum110.

The load measurement device130is operable to measure a material deformation, displacement, stress, strain, and/or vibration of the cradle120at one or more positions. The load measurement device130may include one or more sensors placed at positions on the cradle120to measure the cradle's120material deformation, displacement, stress, strain, or vibration. The load measurement device130may include a sensor located in a position to obtain a single measurement or two or more sensors located in positions where the cradle's120material deformation, displacement, stress, strain, and/or vibration would be more highly concentrated.

In various embodiments, the load measurement device130is operable to employ different sensing methods to determine the material deformation, displacement, stress, strain and/or the vibration of the cradle120. For example, the load measurement device130may comprise position sensors (such as potentiometers, transducers, inductive proximity sensors), strain gauges, load cells, force sensors, ultrasonic microphones, fiber optic cables, acoustic strain gauges, springs, optical interferometers, accelerometers, and gyroscopes to measure the material deformation, stress, strain, or vibration of the cradle120. The load measurement device130may determine material deformation, displacement, stress, strain and/or the vibration along a single axis (e.g., vertically, horizontally, or another desired angle) or along multiple axes.

Material deformation includes elongation, compression, bending, shearing, and twisting of the cradle120. Material deformation of the cradle120is due to the stress the cradle120receives from the weight of the drum110. This results in elongation, compression, bending, shearing, and twisting of the cradle120, which varies depending on the weight of the drum110, including the weight of the load of concrete in the drum110. By comparing the position of the cradle120with the load of concrete in the drum110against the position of the cradle120with no load in the drum110, the load measurement device130is operable to indirectly measure the amount of the load of concrete in the drum110based on the material deformation of the cradle120.

In another embodiment, the load measurement device130may comprise optical displacement transducers, capacitive or inductive displacement transducers, acoustic displacement transducers, or optical interferometers to measure the displacement of the cradle120. Displacement includes how much the cradle120has moved relative to a no-load position. Displacement of the cradle120is due to the stress the cradle120receives from the weight of the drum110. This results in displacement, which varies depending on the weight of the drum110, including the weight of the load of concrete in the drum110. By comparing the position of the cradle120with the load of concrete in the drum110against the position of the cradle120with no load of concrete in the drum110, the load measurement device130is operable to indirectly measure the weight of the load of concrete in the drum110based on the displacement of the cradle120.

In another embodiment, the load measurement device130may comprise accelerometers, gyroscopes, or acoustics such as microphones to measure the vibration of the cradle120. The load measurement device130is also operable to measure the vibration of the cradle120for time-varying deformation. The vibration of the cradle120varies depending on the weight of the drum110, including the weight of the load of concrete in the drum110. By comparing the vibration of the cradle120with the load of concrete in the drum110against the vibration of the cradle120with no load of concrete in the drum110, the load measurement device130is operable to indirectly measure the weight of the load of concrete in the drum110based on the vibration of the cradle120.

By determining the material deformation, displacement, stress, strain, or vibration of the cradle120, it enables the load measurement system100to indirectly determine the amount of the load of concrete currently in the drum110. The load measurement system100is further operable to determine the number of yards of concrete poured into the drum110, currently in the drum110, and poured out of the drum110by determining and analyzing the amount of concrete in the drum110at various times.

The load measurement system100is operable to determine the amount of symmetric or asymmetric load buildup in the drum110. Buildup is concrete that is drying or has dried on the inside of the drum110. Buildup results in the drum110being operable to mix less concrete mix. Buildup also results in damage to the drum110, the drum ring112, and the areas beneath the drum110. Buildup (i.e., dried concrete) forces operators to operate the drum110at a diminished capacity because there is less volume in the drum110for wet concrete.

The shape of the drying or dried concrete in the drum110determines whether the buildup is classified as symmetric or asymmetric. The load measurement device130is operable to classify buildup as symmetric or asymmetric because symmetric buildup, unlike asymmetric buildup, has the identifying characteristic of being akin to measuring a dead load or a static weight on a scale. This is because symmetric buildup is concrete that is uniformly distributed along the axis of the drum's110rotation. For example, when concrete is stuck to the drum100in a symmetrically distributed state, the load measurement system130will report a DC offset or an increase in a measuring signal proportional to the static weight. For the same reasons, symmetric buildup does not vary with time or with drum110rotations.

In contrast, asymmetric buildup is concrete that is not uniformly distributed along the axis of the drum's110rotation. Stated differently, asymmetric buildup is dried concrete concentrated in a single location inside the drum110, while symmetric buildup is dried concrete evenly distributed inside the drum110. The load measurement device130is operable to classify buildup as symmetric or asymmetric because asymmetric buildup, unlike symmetric buildup, has the identifying characteristics of varying with time and being akin to an AC sine wave.

Asymmetric buildup is more damaging to a drum110than symmetric buildup because asymmetric buildup changes the center of gravity of the drum110due to the uneven distribution of dried concrete inside the drum110. Asymmetric buildup also causes a reversal of tooth engagement between a mixing motor gear and a main drum gear, which creates a chattering effect. The load measurement device130is operable to detect the chattering effect as a time-varying effect and thus classify buildup as asymmetric.

Measuring and detecting buildup in the drum110can be used to predict damage to the drum, and thus prevent drum failures with corrective action. Preventing drum failures extends the operative life of the drum110because repairs/maintenance can be performed on the drum110before otherwise critical or incurable defects occur.

In one embodiment, the load measurement system100employs a single measurement of material deformation from the load measurement device130(i.e., a measurement from only one gauge, cell, cable, interferometer, transducer, accelerometer, gyroscope, acoustic, or other sensor) to determine the amount of symmetric load buildup in the drum110. The load measurement system100may also employ a single measurement of displacement from the load measurement device130to determine symmetric load buildup in the drum110.

In another embodiment, the load measurement system100employs multiple measurements of material deformation from several load measurement devices130(i.e., measurements from more than one gauge, cell, cable, interferometer, transducer, accelerometer, gyroscope, acoustic, or other sensor) to determine the amount of symmetric load buildup in the drum110. The load measurement system100may also employ multiple measurements of displacement from several load measurement devices130to determine symmetric load buildup in the drum110.

The load measurement system100is further operable to determine the amount of asymmetric buildup in the drum110.

In one embodiment, the load measurement system100employs multiple measurements from a single load measurement device130(i.e., only one gauge, cell, cable, interferometer, transducer, accelerometer, gyroscope, acoustic, or other sensor) over a period of time using a time-variation analysis (e.g., frequency, Fast Fourier Transform, or Discrete Fourier Transform analysis) to determine the amount of asymmetric load buildup in the drum110.

The load measurement system100is operable to perform a frequency or similar analysis for any load measurement device130to determine the amount of asymmetric buildup currently in the drum110. Based on the power/amplitudes of frequencies from a single load measurement device130over a period of time, the amount of asymmetric buildup currently in the drum110can be determined. By way of example, if the drum110, without any buildup, rotates at a rate of one rotation per second, then there will be a frequency resembling a sine wave at 1 Hertz (“HZ”). If there is asymmetric buildup in the drum110, then the amplitude/power of the frequency from the single load measurement device130will be greater over time. The larger the amount of asymmetric buildup in the drum110, the larger the amplitude/power of the frequency from the load measurement device130.

In another embodiment, the load measurement system100employs measurements of material deformation or displacement from several load measurement devices130(i.e., measurements from more than one gauge, cell, cable, interferometer, transducer, accelerometer, gyroscope, acoustic, or other sensor) to determine asymmetric buildup in the drum110. One advantage of employing multiple load measurement devices130to determine buildup in the drum110is that the load measurement system100is operable to determine the load buildup in the drum110without analyzing the amplitude/power of the frequency of the load measurement devices130over a period of time.

In one embodiment, the load measurement system100is operable to determine the amount of asymmetric buildup in the drum110using microphone data from a load measurement device130to detect and measure characteristic sounds created by asymmetric buildup.

In another embodiment, the load measurement system100is operable to employ machine learning algorithms, such as deep learning, to better predict drum failures based on measurements from the load measurement device130.

The load measurement system100is operable to work with various mixers known and used in the industry, including tilt mixers, stationary mixers, construction vehicle mixers, and mounted construction vehicle mixers.

Referring toFIG.2, preferred locations to measure the cradle's120material deformation, displacement, and/or vibration using an embodiment of a load measurement device130according toFIGS.1A and1Bare illustrated.

In one embodiment, the load measurement device130may be placed horizontally, along the base126of the U-shaped cradle120to measure the material deformation of the cradle120. The load measurement device130may also be placed at an angle (approximately 45 degrees) along the arms128of the U-shaped cradle120to measure the material deformation of the cradle120.

In another embodiment, the load measurement device130may be placed horizontally, along the base126of the U-shaped cradle120to measure the displacement of the cradle120. The load measurement device130may also be placed at an angle (approximately 45 degrees) along the arms128of the U-shaped cradle120to measure the displacement of the cradle120.

In another embodiment, the load measurement device130may be placed horizontally, along the base126of the U-shaped cradle120to measure the vibration of the cradle120. The load measurement device130may also be placed at an angle (approximately 45 degrees) along the arms128of the U-shaped cradle120to measure the vibration of the cradle120. The load measurement device130may further be placed on a stationary frame adjacent to the cradle120to measure the vibration of the cradle120.

Referring toFIG.3, strain in the horizontal direction exhibited by the cradle120of an embodiment of a load measurement system100according toFIGS.1A and1Bis illustrated.FIG.3demonstrates that the horizontal strain on the cradle120is significant at the base126and arms128of the cradle120. In one embodiment, load measurement devices130may be placed at the base126and/or arms128of the cradle120to measure the cradle's120material deformation, displacement, and/or vibration.

Referring toFIG.4, strain in the vertical direction exhibited by the cradle120of an embodiment of a load measurement system100according toFIGS.1A and1Bis illustrated.FIG.4demonstrates that the vertical strain on the cradle120is significant at and arms128of the cradle120. In one embodiment, load measurement devices130may be placed at the arms128of the cradle120to measure the cradle's120material deformation, displacement, and/or vibration.

Referring toFIG.5, a block diagram of a method for sending alerts based on the amount of concrete, symmetric concrete buildup, and asymmetric concrete buildup in the drum110is illustrated.

In step510, the load measurement system100receives a material deformation, a displacement, or a vibration measurement from a load measurement device130adjacent to a cradle120receiving a mixing drum110.

In step520, the load measurement system100determines an amount of concrete in the mixing drum110based on the material deformity, the displacement, or the vibration measurement from the load measurement device130.

In step530, the load measurement system100determines an amount of symmetric concrete buildup in the mixing drum110based on the material deformity, the displacement, or the vibration measurement from the load measurement device130.

In step540, the load measurement system100determines an amount of asymmetric concrete in the mixing drum110based on the material deformity, the displacement, or the vibration measurement from the load measurement device130.

In step550, the load measurement system100sends an alert based on the amount of concrete, symmetric buildup, and asymmetric building in the mixing drum110.

The load measurement system100may proceed from step510to step520, step530, or step540in any order. Depending on the type of alert a user desires to receive, the load measurement system100is operable to omit step520, step530, or step540as needed. By way of example, if a user only desires to know the amount of concrete in the mixing drum110, then the load measurement system100would proceed from step510, to step520, and then to step550—thereby skipping step530and step540. The load measurement system100is similarly operable to only send alerts regarding the symmetric or asymmetric buildup in the mixing drum110.

Sending alerts to remote devices (i.e., computers, tablets, smartphones, etc.) based on measurements from a load measurement device130is beneficial because it informs users of the amount of load of concrete currently in the drum110, as well as the presence or amount of symmetric or asymmetric buildup in the drum110. The alerts may also include information regarding suggested maintenance or repairs to the drum110so that corrective action can be taken to prevent drum failures, such as critical or incurable defects.

Referring toFIG.6, strain in the vertical direction exhibited by the cradle120of an embodiment of a load measurement system100according toFIGS.1A and1Bis illustrated.FIG.6demonstrates that displacement exhibited by the cradle120can be determined based on a difference/change in height (i.e., Y value) between a substantially horizontal reference beam610, reference end pins620, and/or a center pin630. In one embodiment, a substantially horizontal reference beam610may be pinned to end pins620on the substantially U-shaped cradle120. When the cradle120exhibits material deformation, such as bending or curving, the reference beam610remains in a substantially horizontal state. The load measurement system100is operable to measure the displacement of the cradle120based on the distance between the reference beam610and the cradle120after the cradle120exhibits material deformation.

In another embodiment, the load measurement system100is operable to measure the displacement of the cradle120based on the difference/change in height between the end pins620and the center pin630. The center pin630will experience a greater change in height compared to the end pins620because the material deformation of the cradle120, such as bending or curving, is greater at the center of the cradle120than at the end of the cradle120. The pins620,630may be welded or pinned (i.e., not welded) to the cradle120. Welded pins provide long term reliability for measuring the displacement of the cradle120.

Referring toFIGS.7A and7B, a perspective and side view of an embodiment of a load measurement system according toFIG.1is illustrated.FIGS.1A and1Billustrate that the load measurement device130may be an inductive proximity sensor placed adjacent to the cradle120and above a structural channel710(also known as a C-channel or a parallel flange channel). The load measurement device130is operable to measure the displacement of the cradle120by comparing the position of the cradle120at rest against the position of the cradle120when exhibiting material deformation such as bending or curving. The load measurement device130may be adjoined above, below, adjacent to, or along the cradle120with the assistance of brackets or other securing means. The brackets or other securing means must employ a sufficient stiffness to resist flexing or bending relative to the cradle120when the cradle120exhibits material deformation in order for the load measurement device130to record accurate measurements.

In another embodiment, the load measurement system100includes a pad720operable to absorb non-cradle vibrations (i.e., interference), which facilitates the load measurement device130obtain accurate measurements. The non-cradle vibrations may include vibrations from the structural channel710while the drum110is in use, or vibrations from a user stepping on or near the structural channel710. The pad720may be made of rubber or similar sound absorbing materials.

The above description is only to preferred embodiments of the present invention and it should be noted that those skilled in the art can make improvements and modifications without departing from the technical principles of the present invention and as such, variations are also considered to be the scope of protection of the present invention.