Integration and Testing of a Multistack Automated Cone Machine*

................................................................................................................................... v EXECUTIVE SUMMARY .......................................................................................................... vii TABLE OF CONTENTS............................................................................................................... ix LIST OF FIGURES ...................................................................................................................... xii CHAPTER 1: INTRODUCTION................................................................................................... 1 1.1 Background............................................................................................................. 1 1.2 History of Development.......................................................................................... 1 1.3 Testing of ACM 1 ................................................................................................... 2 1.4 Multistack Design ................................................................................................... 2 1.5 Chapter Summaries................................................................................................. 3 CHAPTER 2: AUTOMATED CONE MACHINE OPERATION................................................. 5 2.1 Description of the basic Automated Cone Machine ............................................... 5 2.2 Main Conveyor Belt System................................................................................... 7 2.3 Stowage System.................................................................................................... 10 2.4 Lateral Conveyor Belt........................................................................................... 14 2.5 Drop Boxes ........................................................................................................... 16 2.6 Funnel System....................................................................................................... 18 2.7 Automated Control System................................................................................... 19 2.8 Power Systems ...................................................................................................... 20 CHAPTER 3: MACHINE FUNCTIONAL DESIGN CONSIDERATIONS............................... 23 3.1 Challenge to Automation of Cone Laying ............................................................ 23 3.2 Caltrans Fleet Experience ..................................................................................... 23 3.3 Caltrans Engineering Changes.............................................................................. 24 3.4 Operational Reliability.......................................................................................... 25 3.5 Recommendation for Hydraulic Power ................................................................ 25 3.6 Recommendation for Safe Stand by Mode ........................................................... 26 3.7 Recommendation for ACM Drop Box Operation................................................. 26 3.8 Recommendation for ACM Drop Box Road Clearance ....................................... 26 3.9 Recommendation for Cone Spacing ..................................................................... 27 3.10 Recommendation for Failure Diagnosis ............................................................. 27 3.11 Recommendation for Forward Pick Up .............................................................. 27 3.12 Recommendation for Standardization of Cone Design ...................................... 28 CHAPTER 4: MULTISTACK DESIGN...................................................................................... 29 4.1 High Capacity Machine History ........................................................................... 29 Copyright 2011, AHMCT Research Center, UC Davis x 4.2 Need for a High Capacity Machine ...................................................................... 29 4.3 Consideration of a Reversed Orientation.............................................................. 31 4.4 Consideration of Alternatives to the Two Row Stowage System......................... 32 4.5 Consideration of Vertical Cone Stack Stowage.................................................... 32 4.6 Sizing of the Truck................................................................................................ 33 4.7 Review of Multistack Concepts ............................................................................ 34 4.8 Selected Forklift Design ....................................................................................... 37 4.9 Original Hinge Retraction Mechanism ................................................................. 39 4.10 Original Storage Framework............................................................................... 40 4.11 Operating Sequence ............................................................................................ 42 4.12 Integrated Storage Framework............................................................................ 43 4.13 Stack Storage sequence....................................................................................... 45 4.14 Summary of Multistack Design Development.................................................... 47 CHAPTER 5: RETRIEVAL ARM SYSTEM CONTROL .......................................................... 49 5.