Patent Publication Number: US-2015066290-A1

Title: Indication system for a machine

Description:
TECHNICAL FIELD 
     The present disclosure relates to an indicator system, and more particularly to a light indicator system provided on a machine. 
     BACKGROUND 
     During a loading operation of a machine, it may be required to load the machine with an optimum amount of payload. An overloaded condition of the machine may affect the machine, and sometimes create a general depression or subsidence of the machine. Further, continuous overloading of the machine may even lead to damage or breakdown of the machine. Therefore, a loading tool operator, who resides outside of the machine, may have to be made aware of the amount of payload that is required to be loaded on to the machine, so that the machine does not exceed a threshold weight carrying capacity. 
     For this purpose, visual indication systems are provided on an exterior portion of the machine in order to make the loading tool operator aware of whether a loading capacity of the machine is met during the loading operation. Some machines make use of a three light payload monitor to provide a visual indication to the loading tool operator, in order to make the loading tool operator aware of when the loading capacity of the machine is met. However, these monitors are large, occupy space, and may also have additional costs associated therewith. The wiring and mounting of these monitors may be complex and cumbersome. 
     U.S. Pat. No. 4,835,719 describes a payload monitoring system of a work vehicle includes a software controlled method of predicting when one additional bucketload of material will properly fill the vehicle to its rated capacity. The system calculates the actual magnitude of each bucketload of material and adds that value to the present payload to predict the future payload resulting from an additional bucketload of material. When the predicted future payload encompasses the rated capacity, the system signals the operators of both the work vehicle and the loading vehicle that one additional pass will complete the loading process. 
     SUMMARY OF THE DISCLOSURE 
     In one aspect of the present disclosure, a light indicator system for a machine is disclosed. The light indicator system includes a single light assembly positioned on an exterior facing surface of an operator cab of the machine. The light assembly is positioned such that it is viewable from outside the machine. The light indicator system also includes a payload monitoring module configured to generate a signal indicative of an amount of payload on the machine. The light indicator system further includes a transmission module configured to generate a signal indicative of a mode of operation of the machine. The light indicator system includes a controller communicably coupled to the light assembly, the payload monitoring module, and the transmission module. Further, the controller is configured to receive the signal indicative of the mode of operation of the machine. The controller is also configured to activate a first configuration of the light assembly during a traversal of the machine, such that in the first configuration, the light assembly is configured to display a first indication in a first color. The controller is further configured to activate a second configuration of the light assembly during a parking of the machine. In the second configuration, the controller is configured to display a second indication in a second color on the light assembly. The controller is also configured to receive the signal indicative of the amount of payload. The controller is further configured to compare the amount of the payload with a predetermined threshold. The controller is configured to change the second color to a third color based on exceeding the predetermined threshold. 
     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 an exemplary machine, according to one embodiment of the present disclosure; 
         FIG. 2  is a perspective view of an operator cab of the machine of  FIG. 1  having a light assembly mounted on a top portion of the operator cab; and 
         FIG. 3  is a block diagram of a light indicator system associated with the machine. 
     
    
    
     DETAILED DESCRIPTION 
     Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or the like parts.  FIG. 1  illustrates an exemplary machine  100 . In the illustrated embodiment, the machine  100  is an articulated truck. A person of ordinary skill in the art will appreciate that the machine  100  depicted in the accompanying figures is merely on an exemplary basis and does not limit the scope of the present disclosure. Accordingly, the machine  100  may be any of a mining truck, an off-highway truck, a dump truck, a quarry truck, and the like. It should be noted that the disclosure can be applied to any number of different types of wheeled machines used in industries including, but not limited to, construction, transportation, agriculture, forestry, and waste management. 
     Referring to  FIG. 1 , the machine  100  may have a front section  102  and a rear section  104 . The front section  102  may be provided with a front frame  106 . An operator cabin  108  may be provided on the front frame  106  of the front section  102 . The operator cabin  108  may house various controls of the machine  100 . An enclosure  110  may be provided on the front section  102  which may house a power source (not shown). The power source may provide power to the machine  100  for mobility and/or other operational needs. The power source may include, for example, a diesel engine, a gasoline engine, a gaseous fuel powered engine such as a natural gas engine, a combination of known sources of power, or any other type of power source apparent to one skilled in the art. The power source may alternatively include a non-combustion source of power, such as, a fuel cell, a power storage device, an electric motor, or other similar mechanism. The front section  102  may further include a front wheel set  112 . The front wheel set  112  may include wheels for manoeuvring of the machine  100  on ground. 
     The rear section  104  of the machine  100  may be provided with a rear frame  114 . The rear section  104  of the machine  100  may include a payload carrier  116  provided on the rear frame  114 . The payload carrier  116  may be configured to carry a payload from one location to another. Further the rear section  104  may include a centre wheel set  118  and a rear wheel set  120 . The front and rear sections  102 ,  104  may be linked to each other by an articulated joint  122 . The articulated joint  122  may permit relative movement between the front and rear sections  102 ,  104  about a vertical axis, enabling the machine  100  to be steered. The articulated joint  122  may also permit roll about a longitudinal axis thereby reducing stresses on the front frame  106  and/or the rear frame  114  and increasing wheel contact and traction. Additionally, elements of a powertrain (not shown) for example, a torque converter, transmission inclusive of gearing, one or more drive shafts, differentials, and other known elements of the powertrain may be provided on the machine  100  to transmit power from the power source to the front, centre, and/or rear wheel sets  112 ,  118 ,  120 . 
     The machine  100  also includes one or more input devices  124  (see  FIG. 3 ) for controlling a transmission of the machine  100  and hoisting of the payload carrier  116  relative to the rear frame  114  of the machine  100 , respectively. In one embodiment, the input device  124  may be placed in the operator cabin  108 . For example, any of the input devices  124  can include a lever, a joystick, a switch, a button, a touchscreen, keypad, or the like. The input device  124  may be communicably coupled to a controller  126  (see  FIG. 3 ) of the machine  100 . Based on an input received from the operator, such as a change in position of the input device  124 , the input device  124  may send control signals to the controller  126 , indicative of an operator command for transmission control and/or hoisting control of the machine  100 . Based on the input from the operator, the machine  100  may operate in any one of a park, reverse, neutral, and drive mode. For example, in the drive mode the machine  100  may move on a worksite in order to reach a loading location. Further, when a loading operation is being performed, the machine  100  may be in the park mode, so that while the loading operation is being performed, the machine  100  continues to remain stationary. 
     The controller  126  may embody a single microprocessor, or multiple microprocessors that include a means for controlling and operating components of the light indicator system  134  or the machine  100 . Numerous commercially available microprocessors may be configured to perform the functions of the controller  126 . It should be appreciated that the controller  126  could readily embody a general microprocessor capable of controlling numerous machine functions. The controller  126  may include a database  132 , a memory, a secondary storage device, a processor, and any other components for running an application. Various other circuits may be associated with the controller  126  such as a power supply circuit, a signal conditioning circuit, a driver circuit, and other types of circuits. 
     As shown in  FIG. 3 , a transmission module  128  may be communicably coupled to the controller  126 . The transmission module  128  is configured to generate a signal indicative of the mode of operation of the machine  100 . In one embodiment, the transmission module  128  may include, but not limited to, a sensor, for example, a position sensor, an accelerometer, an inclinometer, a tilt sensor, and/or a pressure sensor. The transmission module  128  is associated with a transmission system of the machine  100 . The transmission module  128  may determine the mode of operation of the machine  100  based on engagement of a gear of the machine  100  or based on a user input via the input device  124 . The modes that may be determined by the transmission module  128  may be indicative of whether the machine  100  is being parked or being made to traverse on the worksite. A person of ordinary skill in the art will appreciate that the controller  126  may control a variety of functions on the machine  100 . 
     The machine  100  includes a payload monitoring module  130 . The payload monitoring module  130  is configured to estimate a weight or amount of payload present within the payload carrier  116  of the machine  100 . Further, the payload monitoring module  130  may be communicably coupled to the controller  126 . The payload monitoring module  130  may include a plurality of sensors (not shown). In one example, the plurality of sensors may be configured to generate a signal indicative of the shear forces acting on a beam of the machine  100 . In one embodiment, the plurality of sensors may be a piezoelectric sensor. Alternatively, the plurality of sensors may include any one or a combination of strain sensors, and/or load cells known to one skilled in the art. For example, the sensor may be a foil or wire type strain sensor, film type strain sensor, semiconductor strain sensor, bonded resistance strain sensor, capacitive strain sensor, hydraulic load cell, pneumatic load cell, strain gauge load cell, or any other sensor configured to detect and/or measure the amount of the payload. Further, the database  132  may be coupled to the controller  126 . The database  132  may store a threshold value of the payload that may be carried by the payload carrier  116 . This threshold value may be indicative of a loading capacity of the machine  100  and may vary based on the application and system design. 
     In one embodiment, the controller  126  may be communicably coupled to a display device (not shown) provided in the operator cabin  108 . The display device may be a display system known in the art, such as, a LED device, a LCD device, a CRT monitor, a touchscreen device, etc. The display device may be configured to display and notify the operator of the machine  100  of the amount of the payload on the machine  100 . In one embodiment, the controller  126  may be communicably coupled to a control station located remotely with respect to the machine  100 . In such an embodiment, the controller  126  may be configured to notify the operator and/or site manager present at the control station of the amount of the payload on the machine  100 . 
     The machine  100  of the present disclosure includes a light indicator system  134 . Referring to  FIGS. 1 ,  2 , and  3 , the light indicator system  134  includes a single light assembly  136 . The light assembly  136  is embodied as a visual indication means. The light assembly  136  is a singular assembly which may be positioned on an exterior facing surface of the operator cabin  108  of the machine  100 . The light assembly  136  is mounted such that the light assembly  136  is viewable to a person standing outside of the machine  100 . In the illustrated embodiment, the light assembly  136  is mounted on a top portion of the operator cabin  108  (shown in  FIGS. 1 and 2 ). Further, the light assembly  136  is communicably coupled to the controller  126 . The light assembly  136  may include any known lighting or signaling device capable of illumination, on receiving control signals from the controller  126 . The light assembly  136  may embody any of a known incandescent lamp, Light Emitting Diodes (LED), High Intensity Discharge (HID) lamps, neon bulbs, halogen bulbs, xenon lamps, and the like. Referring to  FIG. 2 , in the illustrated embodiment, the light assembly  136  is an LED strobe including a LED  138  and a cover  140 . In one example, the LED  138  may be selected such that the LED  138  is capable of changing colors. Alternatively, the light assembly  136  may include three LED&#39;s present within the singular assembly such that each LED is capable of illuminating in distinct colors. 
     As explained earlier, the controller  126  is communicably coupled to the transmission module  128 , and is configured to receive control signals therefrom. The controller  126  is also communicably coupled to the light assembly  136 . The light assembly  136  of the light indicator system  134  is operable in a first configuration and a second configuration. 
     In the first configuration, the light assembly  136  operates as a beacon, in order to indicate a traversal of the machine  100  on the worksite. The light assembly  136  operates in the first configuration when the machine  100  is in the drive mode or is traversing on the worksite in a forward or reverse direction. On determining that the machine  100  is in the drive mode, based on signals received from the transmission module  128 , the controller  126  may further send signals to the light assembly  136  to activate the LED  138  of the light assembly  136 . Further, in the first configuration, the light assembly  136  is configured to display a first indication in a first color. The first configuration of the LED  138  may include flashing of the LED  138 . The first color may include white, amber, yellow, or any other color as required. For example, when the light assembly  136  is activated to operate in the first configuration, the light assembly  136  may operate as a strobe beacon, such that the LED  138  produces regular flashes of amber light. In one embodiment, the LED  138  may also rotate during the traversal of the machine  100 . 
     When the machine  100  switches to the park mode, the controller  126  may send control signals to the light assembly  136  in order to operate the light assembly  136  in the second configuration. In the park mode, the machine  100  may be in a state ready to receive the payload into the payload carrier  116 . Accordingly, in the second configuration, the light assembly  136  may indicate or notify the person exterior to the machine  100 , about the stationary state of the machine  100 . In the second configuration, the light assembly  136  is configured to display a second indication in a second color. The second indication may include a steady or solid light representation. The second color may include any color, such as, green color. In one example, the LED  138  of the light assembly  136  may turn green in color to indicate that the machine  100  is in the park mode. Further, the LED  138  may glow of a steady green color. This may indicate to the person outside of the machine  100  that the machine  100  is ready to be loaded with the payload. Accordingly, the light assembly  136  may indicate to the operator that the machine  100  is parked for the loading operation to begin. 
     As discussed earlier, the controller  126  of the present disclosure is also communicably coupled to the payload monitoring module  130 . The payload monitoring module  130  may estimate the amount of the payload loaded into the payload carrier  116  of the machine  100  during the loading operation. The payload monitoring module  130  may be manually or automatically activated. During the loading operation, the light assembly  136  may continue to be in the second color, for example, the light assembly  136  continues to glow of the green color. 
     The payload monitoring module  130  may send control signals indicative of the amount of payload present within the payload carrier  116  to the controller  126 . The controller  126  may retrieve the predetermined threshold stored within the database  132  and compare the signal of the estimated amount of the payload received from the payload monitoring module  130  with the predetermined threshold. 
     When the amount of payload being loaded in to the payload carrier  116  exceeds the predetermined threshold, the controller  126  generates a signal indicating an overload condition of the payload carrier  116  of the machine  100 . The controller  126  may send signals to the light assembly  136  during the overload condition. Based on the overload condition of the payload carrier  116 , the light assembly  136  of the light indicator system  134  is configured to change the display of the LED  138  from the second color to a third color. For example, the LED  138  may change from green color to red color, indicating the overload condition of the payload carrier  116 . Further, in one example, the LED  138  may glow of a steady red color. 
     Once the operator believes that the payload is sufficient, the operator can provide input to the input device  124  to put the machine  100  in the drive mode or begin traversing on the worksite in a forward or reverse direction. On determining that the machine  100  is in the drive mode, based on the signals received from the transmission module  128 , the controller  126  may further send signals to the light assembly  136  to activate the LED  138  of the light assembly  136  to the first configuration from the second configuration. 
     In one embodiment, the light indicator system  134  may also include an audio means associated therewith. The audio means may also be communicably coupled with the controller  126 . During the overload condition of the payload carrier  116 , the audio means may trigger an alarm sound based on the signals received from the controller  126 . The visual and audio means may together notify the person exterior to the machine  100  regarding the overload condition of the payload carrier  116 . 
     It should be noted that the light indications explained above are merely on an illustrative basis and do not limit the scope of the present disclosure. Further, the colors described herein are also exemplary in nature and may vary based on the system requirements. The representation of the light assembly  136  may also vary and is not limited to that described herein. For example, the light assembly  136  may be embodied as a rectangular light extending along a length of a roof portion of the machine  100 . Further, there may be modes when the first configuration and the second configuration are not activated as set forth above. For example, when the machine  100  is traversing on the worksite, but the operator places the input device  124  in the park mode or braking mode but not for loading. Here, the controller  126  may send signals to maintain the first configuration, especially when the payload monitoring module  130  sends control signals indicative of the loaded amount of payload present within the payload carrier  116  to the controller  126 . Also, when the machine  100  is dumping material from the payload carrier  116 , the operator may place the input device  124  in the park mode or braking mode. Here, the controller  126  may send signals to maintain the first configuration, especially when the payload monitoring module  130  sends control signals indicative of the changing loading amount of payload present within the payload carrier  116  to the controller  126 . 
     INDUSTRIAL APPLICABILITY 
     In order to perform the loading operation, a loading tool operator present exterior to the machine may need to be made aware of the mode of operation and also a loading status of the machine. An overloaded condition of the machine may affect a service life of the components of the machine and may also lead to damage or breakdown of the machine. Further, a productivity of the loading operation may depend on the skills of the operator external to the machine for loading the machine with an optimum amount of payload. However, the skills and perceptions may vary from one operator to another. 
     The present disclosure relates to the light indicator system  134 . The light assembly  136  of the light indicator system  134  displays the first indication in the first color, when the machine  100  is in the drive mode. Also, when the machine  100  is in the park mode, the controller  126  sends signals to the light assembly  136  to display the second indication in the second color. Further, during the loading operation, if the amount of payload being loaded into the payload carrier  116  exceeds the predetermined threshold, the second color changes to the third color, thereby indicating the overload condition of the machine  100 . In another embodiment, the operator can use the input device  124  to manually switch between the first configuration and the second configuration of the light assembly  136 . For instance, when the machine  100  is ready for a loading cycle, the operator can switch the input device  124  to a mode to permit the light assembly  136  to operate in the second configuration. Once the operator is ready to leave the loading cycle, the operator can switch the input device  124  to a mode to permit the light assembly  136  to operate in the first configuration. 
     The light indicator system  134  disclosed herein is compact in size and may be easily retrofitted to an existing machine. Further, the light indicator system  134  is cost effective and has reduced wiring and mounting complexities. The light assembly  136  may be easily assembled onto the machine  100 . 
     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 what is disclosed. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.