Systems and methods for bucket agitation during automatic load dumping.

Abstract

A wheel loader includes a bucket configured to hold a predetermined load of granular or powdered material; a hydraulic system having an electro-hydraulic actuator to move and rock the bucket at an angle; a hydraulic sensor configured to detect hydraulic pressure; an interface configured to receive input parameters and output bucket status information; and a controller. The input parameters include a target weight of the granular or powdered material. The detected hydraulic pressure is used to determine the status information, including the weight of the granular or powdered material in the bucket. The controller is configured to control the hydraulic system to tilt the bucket to a predetermined angle and rock the bucket according to an agitation pattern until the weight of the granular or powdered material in the bucket is equal to or less than the target weight of the granular or powdered material.

Description

Technical Field

[0001] The present invention generally relates to a construction vehicle having a bucket and an automatic payload unloading system, and more specifically to a wheel loader machine and a method for agitating the loader bucket during automatic payload unloading. Background Technology

[0002] On construction sites such as excavation, open-pit mining, construction, and agriculture, site loader-type machines such as wheel loaders, track loaders, and backhoe loaders are relied upon to load loose, payload materials into transport vehicles such as road transport trucks. It is important that the transport trucks are fully loaded to their maximum capacity to avoid underloading or overloading situations that may be undesirable from a productivity and efficiency standpoint.

[0003] Typically, loader-type machines have a payload control system that accurately measures the payload in the bucket. Once activated, the payload control system sums the payload of successive bucket operations to determine an estimate of the payload already loaded into the haul truck. During the final pass, the operator adjusts the final amount of payload in the bucket to be dumped onto the stack or directly from the bucket into the haul truck. This process is called tip-off or tipping-off. The former is called stack tipping, where onboard sensors determine the load in the bucket, and the operator dumps the excess payload onto the stack. The latter is called truck tipping, where the operator loads the bucket and partially empties it into the haul truck until the target payload capacity is reached.

[0004] A strategy described in co-owned U.S. patent application 2020 / 0263384 involves an automated payload target dumping process for loading transport vehicles. This dumping includes a slow dumping sequence in which multiple dumps are performed followed by actuation to induce and prevent material spillage until the remaining payload target is met. The types of materials the bucket can carry can range from rock, stone, gravel, and dust to fine-grained materials and powders. For diverse materials with significantly different packing properties, angles of repose, cohesion, and densities, a slow dumping sequence during the dumping process can be unreliable. Furthermore, it can be difficult to determine when material will spill, how it will spill a certain volume, and how it will stabilize (how the material in the bucket will prevent spillage). This is especially true for materials with non-smooth flow. For example, fine-grained or powdery materials tend to be sticky, making them difficult to spill to achieve the payload target.

[0005] One method of loading material involves vibrating the bucket before it overflows to shake and release the material. U.S. Patent No. 7,117,952 to Bares et al., published October 10, 2006, discloses an automatic attachment vibration system comprising an automatic vibration mechanism for automatically vibrating the attachment member in response to an activation signal. The automatic vibration of the attachment member can be used to shake out the attached bucket, to dig the bucket into the material, or to pack the material with the bucket. This method provides the ability to achieve desired loads within improved tolerances. For example, a method for handling a 10-ton load of fine-grained material can be achieved within tolerances of approximately 5 / 10 to 6 / 10 tons. However, depending on the type of material, applying vibration can lead to inconsistent results and is therefore often unreliable. Furthermore, applying vibration before overflowing to shake and release the material may require multiple shakes of the bucket, which is time-consuming.

[0006] The disclosed systems and methods for agitating the loader bucket during automated payload dumping for loading transport vehicles are designed to overcome one or more of the aforementioned problems. Summary of the Invention

[0007] In one aspect, a method for controlling the movement of a bucket is disclosed, the bucket having at least one electrically controlled actuator controlled by a control signal from a computer controller upon receiving a sensor signal from at least one hydraulic sensor associated with the bucket. The method may include receiving a target weight of particulate or powdered material; receiving an agitation pattern having one or more frequencies and one or more amplitudes over a time period; detecting, via the sensor signal, that the weight of the particulate or powdered material in the bucket is within the target weight at a final bucket load; measuring the weight of the particulate or powdered material via the sensor signal and updating the remaining amount to achieve the target weight; overflowing a portion of the particulate or powdered material from the bucket according to the agitation pattern; simultaneously performing the overflow from the bucket and, according to the agitation pattern, shaking the bucket to agitate the particulate or powdered material and updating the remaining amount; and performing the overflow and the shaking according to the agitation pattern until the remaining amount is equal to or less than the target weight.

[0008] On the other hand, the construction vehicle may include an electro-hydraulic system, a bucket operated by the electro-hydraulic system, and an automatic dumping system including an agitation system. The automatic dumping system may include input / output devices configured to receive inputs of control parameters and output bucket status information; and a controller configured to receive inputs of corresponding plurality of hydraulic pressures from the electro-hydraulic system, generate control signals for controlling the electro-hydraulic system to operate the bucket, and, when the controller generates control signals for the dumping motion of the bucket, automatically control the agitation system to generate a rocking motion of the bucket, thereby overflowing particulate or powdery material according to the agitation mode.

[0009] On the other hand, a wheel loader machine is disclosed. The wheel loader machine may include a bucket configured to hold a predetermined load of granular or powdered material; a hydraulic system having at least one electro-hydraulic actuator to move and rock the bucket within a tilt angle and a yaw angle range; a hydraulic sensor configured to detect at least one hydraulic pressure in the hydraulic system; an input / output interface configured to receive input parameters and output state information of the bucket, the input parameters including a target weight of the granular or powdered material, the state information including the weight of the granular or powdered material in the bucket determined based on the at least one hydraulic pressure detected by the hydraulic sensor; and an automatic dumping system including an agitation system, the automatic dumping system including a controller configured to control the hydraulic system to tilt the bucket to a predetermined tilt angle and rock the bucket according to an agitation mode until the weight of the granular or powdered material in the bucket is equal to or less than the target weight of the granular or powdered material. Attached Figure Description

[0010] Figure 1 It is a schematic side view of a wheel loader machine for construction sites according to one or more embodiments of the disclosed subject matter.

[0011] Figure 2 It is a block diagram of a control system for controlling the automatic unloading of a bucket, according to one or more embodiments of the disclosed subject matter.

[0012] Figure 3 This is a flowchart of an automatic bucket payload unloading method according to one or more embodiments of the disclosed subject matter.

[0013] Figure 4 This is a flowchart of the steps for automatic dumping according to one or more embodiments of the disclosed subject matter.

[0014] Figure 5 It is a flowchart of steps in an automated dumping process including agitation, according to one or more embodiments of the disclosed subject matter.

[0015] Figure 6 This is a flowchart detailing a dumping step with agitation according to an agitation mode, based on one or more embodiments of the disclosed subject matter.

[0016] Figure 7 It is a flowchart of steps in automated dumping according to one or more embodiments of the disclosed subject matter, including dumping with agitation in the case of rough materials.

[0017] Figure 8This is a flowchart of steps in automated dumping according to one or more embodiments of the disclosed subject matter, including dumping with agitation in the case of medium-grained materials.

[0018] Figure 9 This is a flowchart of steps in automated dumping according to one or more embodiments of the disclosed subject matter, including dumping with agitation in the case of fine-grained materials.

[0019] Figure 10 It is a flowchart of steps in automated dumping according to one or more embodiments of the disclosed subject matter, including dumping with agitation in the case of powder materials.

[0020] Figure 11 It is a flowchart of the steps for adjusting the coarse agitation mode and duration according to one or more embodiments of the disclosed subject matter.

[0021] Figure 12 This is a flowchart of steps for adjusting the moderate agitation mode and duration according to one or more embodiments of the disclosed subject matter.

[0022] Figure 13 It is a flowchart of the steps for adjusting the fine agitation mode and duration according to one or more embodiments of the disclosed subject matter.

[0023] Figure 14 This is a flowchart of steps for adjusting the powder agitation mode and duration according to one or more embodiments of the disclosed subject matter.

[0024] Figure 15 It is a diagram of the architecture of a neural network for adaptively determining changes in material weight based on agitation patterns, according to one or more embodiments of the disclosed subject matter.

[0025] Figure 16 It is a diagram of an architecture of a recurrent neural network for determining a churning pattern as a sequence, according to one or more embodiments of the disclosed subject matter. Detailed Implementation

[0026] Various aspects of the invention will now be described in detail with reference to the accompanying drawings, wherein, unless otherwise specified, the same reference numerals refer to the same elements throughout the text.

[0027] Embodiments of the disclosed subject matter relate to a construction vehicle having a bucket and an automatic dumping system having an agitation system to achieve a target load in the bucket. The construction vehicle may include loader-type machines, such as wheel loaders, track loaders, backhoe loaders, etc. For the sake of simplicity in the description of the automatic dumping system, a wheel loader will be used herein as a non-limiting example of a loader-type machine. Figure 1This is a schematic side view of a wheel loader machine 102 for a construction site 100, according to one or more embodiments of the disclosed subject matter. See also Figure 1 An exemplary wheel loader machine 102 is shown at site 100. The wheel loader machine 102 is typically a machine with a movable bucket 118 for digging.

[0028] The wheel loader machine 102 includes a frame or chassis 106. A power source (not shown) is mounted on the frame 106 of the wheel loader machine 102. The power source can be any power source known in the art, such as an internal combustion engine, an electric motor, a power storage device such as a battery, and a hybrid engine. The power source is configured to provide power to the wheel loader machine 102 to meet operational and mobility requirements. The wheel loader machine 102 includes a set of ground engagement members 110, such as wheels. As shown, the pair of ground engagement members 110 may include tracks. The ground engagement members 110 are configured to provide mobility to the wheel loader machine 102 on the ground. The wheel loader machine 102 also includes a powertrain 108, also referred to as a drivetrain, coupled to the power source and the ground engagement members 110. The powertrain 108 may include a transmission assembly having one or more gears, shafts, differentials, torque converters, hydraulic pumps, or motors, etc. The power system 108 can be configured to transmit power from a power source to the ground engagement member 110 and to supply the generated power to other components of the wheel loader machine 102.

[0029] The wheel loader machine 102 includes a linkage assembly 112 pivotally coupled to a frame 106. The linkage assembly 112 includes at least one link member 114 pivotally coupled to the frame 106 and a support arm 116. A bucket 118 is pivotally coupled to the link member 114. The linkage assembly 112 also includes a lifting cylinder 124 for moving the link member 114 and the coupled bucket 118 relative to the frame 106 of the wheel loader machine 102.

[0030] The linkage assembly 112 is configured to perform tasks such as earthmoving, excavation, digging, and dumping. Furthermore, the linkage assembly 112 can be controlled electrically, mechanically, hydraulically, pneumatically, or in combination thereof. The wheel loader machine 102 also includes an operator's cabin 120 disposed on the frame 106 of the wheel loader machine 102. The operator's cabin 120 includes an operator interface, such as a touch display device 122.

[0031] During operation of the wheel loader 102, the linkage 114 and bucket 118 can be moved to different positions to perform a dumping operation. A hydraulic or pneumatic system (not shown) can be used to realize the movement of the linkage 114, the boom 116, and / or the bucket 118 of the linkage assembly 112. For example, a lift cylinder 124 and a tilt cylinder 126 can realize and control the movement of the bucket 118. Cylinders 124 and 126 can be either hydraulic or pneumatic cylinders. Based on the movement of the linkage 114 and the bucket 118, the wheel loader 102 can perform various operations, such as moving, digging, dumping, excavating, etc.

[0032] The dumping operation may require unloading the required amount of load from bucket 118 into haul truck 104 (referred to as truck dumping) or may require unloading excess material from the load onto a pile (referred to as pile dumping). Dumping refers to the process of overflowing a portion of the load material from bucket 118 according to operational requirements. For example, an operator of a wheel loader with an 18-ton bucket capacity may need to load a 45-ton capacity haul truck 104 to its maximum capacity. The loader operator's goal is to load the same amount of tonnage into haul truck 104 in the shortest amount of time while consuming the minimum amount of fuel required by the loader, in order to achieve peak efficiency and reduce operating costs. The operator must also load haul truck 104 within the load tolerance without overloading it. Loading haul trucks within the desired load tolerance requires considerable skill from the operator. For example, to obtain a 45-ton capacity, the operator may dump twice through the loader bucket 118 at its maximum capacity to obtain 36 tons. In the final pass, the operator must dump only 9 tons of material to achieve the required effective load. Depending on the operator's skill, the final pass can be done 3 to 5 times anywhere, provided the first two passes are successful.

[0033] To reduce the duration of final pass and the total time to achieve the target payload in the haul truck 104, the wheel loader machine 102 includes a payload detection system (PDS) 130. PDS 130 includes a dump controller 132 and at least one sensor for generating electronic signals related to the weight of the material in the bucket 118 and electronic signals related to the angle of the bucket 118. In one embodiment, PDS 130 includes a lift pressure sensor 134 associated with a lift cylinder 124 and a tilt pressure sensor 136 associated with a tilt cylinder 126 to detect hydraulic fluid pressure within the respective cylinders 124, 126. The fluid pressure signals associated with the respective cylinders 124, 126 can be used individually or in combination to determine the weight of the material in the bucket 118. PDS 130 may include a lift displacement sensor 138 associated with the lift cylinder 124 and a tilt displacement sensor 140 associated with the tilt cylinder 126. The displacement signals associated with the respective cylinders 124, 126 and the fluid pressure signals can be used to determine the weight of the material in the bucket 118. The PDS130 may also include an inertial measurement unit (IMU) 142, which includes circuitry capable of generating signals representing the position, velocity, motion, and orientation of the linkage assembly 112 and / or the bucket 118, which can be used to determine the weight of the material within the bucket 118. It should be understood that the PDS130 may include any number of measuring devices and sensors depending on the specific requirements of a particular field application not specifically described herein.

[0034] The dump controller 132 may include at least one processing unit 150, or be coupled to it as part of the PDS 130, which is configured to perform the functions of the dump controller 132. The processing unit 150 may include a single microprocessor or multiple microprocessors, comprising components for receiving and monitoring sensor signals from the PDS 130 of the wheel loader machine 102. For example, the processing unit 150 is configured to receive fluid pressure signals from lift and tilt pressure sensors 134, 136; displacement signals from lift and tilt displacement sensors 138, 140; and position, speed, motion, and orientation signals from the IMU 142. It should be understood that the processing unit 150 can be readily embodied in a general-purpose machine microprocessor capable of controlling multiple machine functions.

[0035] The dump controller 132 may also include a memory module 152, or be coupled to the memory module 152 as part of the PDS 130. The memory module 152 may be, for example, one or more data storage devices or another component or circuit that can be used to execute computer-executable instructions stored in the memory module 152. It should be understood that various computer-executable instructions, applications, computer program products, or other aspects, typically described as stored in memory, may also be stored on or read from various non-transitory computer-readable media, such as, but not limited to, computer chips and auxiliary storage devices, including hard disks, floppy disks, optical media such as CD-ROMs and DVDs, or other forms of RAM or ROM.

[0036] The processing unit 150 may be configured with an arithmetic unit to arithmetically determine the weight of the material in the bucket 118, individually or in combination, based on any one of the sensor signals, according to a predetermined mathematical relationship stored in the memory module 152. The memory module 152 may store historical payload weight data to determine, for example, the total weight of the material loaded into the trailer truck 104 during the loading process. The processing unit 150 also includes an arithmetic unit for arithmetically determining the angle of the bucket 118, individually or in combination, based on any one of the sensor signals, according to a predetermined mathematical relationship stored in the memory module 152.

[0037] Figure 2 This is a block diagram of a control system for controlling the electro-hydraulic operation of a bucket. The control system includes an operator interface, such as a display device 122, operation buttons 220, a dump controller 132, and a hydraulic system 240 having at least one, preferably two or more, electro-hydraulic actuators including tilt cylinders 124, 126. The display device 122 can display the estimated total remaining weight of material to be loaded into the trailer truck 104 in display area 201, and the current weight of material currently in the bucket 118 in display area 203. The estimated total remaining weight of material varies with the current weight of material in the bucket 118. When the current weight of material overflows from the bucket 118, the estimated total remaining weight of material decreases by the same amount. The display device 122 may also include input functions, including a material type input 205 for the material type and a target (total) weight input 211 for the target (total) weight of material to be loaded into the trailer truck 104. The display device 122 can display the dumping churning profile in display area 207 and the operating status in display area 209.

[0038] The operation buttons 220 may include an automatic dump button 221, an automatic dump button 223 with agitation, and a confirmation button 225. The confirmation button 225 is used to lock the weight of the material currently in the bucket 118 as the amount to be loaded into the trailer truck 104.

[0039] Figure 2 The layout of the display areas and buttons shown is merely exemplary. Other configurations of additional display areas and buttons are not excluded, as are the possible omissions of some such display areas and buttons.

[0040] The dump controller 132 may be a microcontroller with analog and / or digital inputs and outputs, and a digital-to-analog (D / A) converter and an analog-to-digital (A / D) converter for converting analog input or output signals as needed. Inputs to the dump controller 132 include a pressure signal 233 from the hydraulic system 240. Hydraulic pressure may be obtained using one or more hydraulic sensors 134, 136. Outputs of the dump controller 132 include a hydraulic system control signal 231 with waveform, amplitude, and frequency. The hydraulic system control signal 231 controls the actuation of electro-hydraulic actuators, including a lifting cylinder 124 and a tilting cylinder 126. The dump controller 132 includes a memory module 152 to store one or more control signal patterns, including one or more agitation patterns.

[0041] Industrial applicability

[0042] Wheel loader 102 can be used to load towing truck 104. Wheel loader 102 can perform various operations on the site. In one example, wheel loader 102 can perform a payload dumping operation. More specifically, wheel loader 102 can dump payloads into towing truck 104. Towing truck 104 can include machines such as dump trucks, mining trucks, or any other machine capable of holding and transporting payloads from one location on site 100 to another. Alternatively, wheel loader 102 can dump payloads into piles, hoppers, or other payload receivers at site 100.

[0043] During automatic dumping, agitation is applied to induce dumping of various types of material in a predictable manner. To achieve a material weight substantially within the target weight in a minimal amount of time, the dumping controller 132 controls the excavation and deposition of material into the haul truck 104 via the dumping and inspection process, while the amount of material is within a single dig to achieve the target load of the haul truck 104. During dumping and inspection, dumping is performed by gradually or in fixed increments adjusting the tilt angle of the bucket 118. Inspections can be performed periodically during dumping, or when the bucket 118 is tilted to prevent further overflow. As described later, inspections during dumping and inspection may include measuring the weight of the material in the bucket 118. The dumping and inspection process can be automated by pressing either the automatic dumping button 221 or the automatic dumping button 223 with agitation. The automatic dumping button 221 or the automatic dumping button 223 with agitation may need to be held downwards during operation to ensure the operator intends to use automation. Releasing the button cancels automation. The unloading and inspection process can be performed in two steps: a large amount of overflow followed by fine unloading and inspection of the bucket 118. In the case of automatic unloading with agitation, agitation can be used to perform even finer unloading and inspection of the bucket 118.

[0044] Agitation can be achieved by executing a waveform agitation pattern. This agitation pattern can be achieved by rocking the bucket 118 during dumping, according to a flicking motion and / or a buzzing motion of the bucket, under the control of the dump controller 132 and electro-hydraulic actuators (including the lifting cylinder 124 and the tilt cylinder 126). The bucket 118 can be rocked by the movement of the lifting cylinder 124, the tilt cylinder 126, or by the simultaneous or alternating movement of the lifting cylinder 124 and the tilt cylinder 126. The agitation pattern can include flicking motions and / or buzzing motions executed according to waveforms with gradually changing amplitude and / or frequency. Fine dumping and inspection can be repeated two or three times each time using the same or different agitation patterns. The decision of when to dump, agitate, or perform a combination of both can be made based on the remaining overflow weight and the expected material behavior known by the operator and / or the dump controller 132 from the amount of material overflowed during previous actions.

[0045] Figure 3This is a flowchart of the bucket agitation method. The method is executed by a dump controller 132, which controls the actuation of the lifting cylinder 124 and the tilting cylinder 126 via hydraulic system control signals 231 and pressure signals 233. A display device 122 receives inputs and displays the controller's output information. The operator can input the type of material to be excavated and loaded into the trailer truck via the display device 122. In S301, the dump controller 132 can receive the type of material to be loaded at material type input 205. In one or more embodiments, the material type is an optional input. The operator can input the target weight of the material to be loaded into the trailer truck 104. In S303, the dump controller 132 receives the target weight of the material at target weight input 211.

[0046] The electro-hydraulic operated bucket 118 can perform some initial large-scale digging. The electro-hydraulic operated bucket 118 can scoop any amount of material into the bucket 118. In S307, the wheel loader machine 102 measures the weight of the material in the bucket 118. The weight of the material in the bucket 118 can be measured as a pressure signal 233 based on the pressure in the hydraulic system 240. The current weight of the material in the bucket 118 can be displayed in the display area 203. In S309, the dump controller 132 determines the remaining weight of material that needs to be loaded into the haul truck 104 to achieve the target weight of the material.

[0047] In S311, the dumping controller 132 determines whether the weight of the material in the bucket 118 is higher than the amount of material required to reach the target weight. When the weight of the material exceeds the amount required to reach the target weight ("Yes" in S311), an automatic payload dumping process can be executed.

[0048] In S313, the automated payload dumping process can be initiated by pressing and holding the button and / or lever (as described above, holding is to ensure the operator continues to intend to use the automation); the automated dumping button 221 or the automated dumping button 223 with agitation is an example of a button that can be pressed and held. In one embodiment, the button can be pressed to prepare for automated dumping, and then the lever can be held to indicate continued consent. Releasing the lever cancels the automation.

[0049] Figure 4This is a flowchart of the steps in the automatic dumping process when the automatic dumping button 221 is pressed. When the weight of the material is higher than the material's threshold weight (yes in S401), in S403, the initially executable portion overflows in large quantities to bring the weight of the material in the bucket 118 below the threshold weight. The threshold weight can be a predetermined weight higher than the target weight of the material. If the weight of the material is the target weight (yes in S405), automatic dumping is not required, and the dumping process ends. At the point where the material weight is lower than the threshold (no in S401) and greater than the target weight (no in S405), in S407, the bucket dumps within a predetermined dumping angle and time period. In S409, the weight of the material in the bucket is checked at the end of the time period. When the weight of the material is greater than the target weight (no in S411), in S413, dumping can be adjusted. Depending on how close the material weight is to the target weight, dumping can be adjusted by rocking the bucket harder or softer. Dumping can be adjusted by increasing or decreasing the bucket's tilt angle. The automatic payload unloading process in steps S407 and S409 can be repeated two or three times. The unloading process ends when the weight of the material in the bucket is substantially the target weight (yes in S411). In some embodiments, a second threshold can be set to indicate when the target weight of the material has been achieved within a predetermined tolerance level.

[0050] Figure 5 This is a flowchart of the steps in the automatic dumping process when the automatic dumping button 223 with agitation is pressed. Automatic dumping with agitation is performed under the control of the dumping controller 132 of the control hydraulic system 240.

[0051] During a dumping process with agitation, dumping and inspection can be repeated while performing an agitation pattern. The agitation pattern is a signal waveform shape with amplitude and frequency characteristics. This signal waveform shape is used by the dumping controller 132 to control the actuation of the hydraulic system 240 according to the hydraulic system control signal 231. The amplitude of the signal waveform causes the hydraulic system 240 to fluctuate at an amplitude proportional to the signal amplitude. The frequency of the signal waveform shape causes the hydraulic system 240 to fluctuate at a rate proportional to the frequency. The agitation pattern can be adjusted by changing the amplitude, frequency, and / or waveform shape. For example, the amplitude of the agitation pattern can begin with a flicking motion of a certain amplitude, and then adjust back as the weight of the material gets closer to the target weight. The agitation pattern may include one or more flicking motions followed by a rapid buzzing motion (increased frequency). The agitation pattern may also include a rapid buzzing motion followed by one or more flicking motions, or it may include intermittent flicking motions and rapid buzzing motions.

[0052] The agitation mode may include actuating the hydraulic system 240, including the electro-hydraulic lift cylinder 124 and / or tilt cylinder 126, at a certain speed and frequency, preferably in the form of a sine wave, sawtooth wave, or pulse signal. The electro-hydraulic tilt cylinder 126 may be actuated in a pulse motion that generates agitation of the bucket 118 in a single direction. In one embodiment, the electro-hydraulic tilt cylinder 126 may be actuated in a pulse motion that rapidly generates agitation of the bucket 118 in alternating directions. In one embodiment, agitation of the bucket 118 may be achieved by applying pulse motion to the lift cylinder 124 for connection to the linkage member 114 of the bucket 118. Some particularly compacted materials may require agitation, including an initial automatic rocking motion, to break up the material. For most fine, viscous materials, agitation can achieve faster overflow than unagitation and has improved precision during dumping operations.

[0053] Reference Figure 5 In S501, an automatic dumping process with agitation is performed according to the initial agitation mode. In S503, the weight of the material is checked to determine whether the remaining weight of the material in the bucket 118 is less than the agitation threshold. When the remaining weight of the material is less than the agitation threshold (yes in S503), in S505, the agitation mode can be maintained or optionally adjusted. The adjustment of the agitation mode may include adjusting the duration of the agitation mode application. The agitation mode can be adjusted by changing the amplitude and / or frequency of the signal waveform, or by replacing the signal shape with a new signal shape. If the weight of the material becomes the target weight, when the automatic dumping process with agitation is performed according to the initial agitation mode in S501 (yes in S511), no further automatic dumping is required, and the dumping process ends.

[0054] In S507, dumping with agitation is performed using an optional adjusted agitation mode or a maintained agitation mode (e.g., the agitation mode of S505).

[0055] In S509, the dumping controller 132 checks whether the remaining weight of the material in the bucket 118 is less than or equal to a final threshold. The final threshold can be based on a predetermined tolerance level that is substantially less than the agitation threshold in S503. When the remaining weight of the material is still greater than the final threshold (no in S509), the agitation mode is optionally adjusted or maintained again in S505, and dumping with agitation is performed again in the agitation mode in S507. The process of adjusting or maintaining the agitation mode in S505 and dumping with agitation in S507 is repeated until the remaining weight of the material is less than the target weight (above the zero tolerance of the target weight) and within the final threshold (yes in S509).

[0056] To obtain accurate weight measurement, the weight can be measured based on the hydraulic pressure in the hydraulic system 240 during the tilting and inspection process by filtering out noise caused by agitation. Pressure fluctuations in the electro-hydraulic cylinders 124 and 126 and the payload in the bucket cause noise in the weight measurement. Historical noise signals during agitation can be analyzed to obtain the characteristics of the agitation noise signal. During tilting and inspection, the pressure signal 233 can be filtered to remove noise caused by agitation and obtain a more accurate measurement of the material weight. Furthermore, noise caused by machine resonant frequencies can be analyzed to obtain the characteristics of machine noise. Machine resonant noise can be filtered to obtain a more accurate measurement of the material weight. Weight measurement can be performed periodically during the unloading of the bucket 118 during the unloading and inspection process.

[0057] Figure 6 This is a flowchart detailing the dumping steps under agitation according to the agitation mode. In S601, the bucket 118 is dumped while a predetermined agitation mode is applied. In S603, the dumping controller 132 receives a pressure signal 233 from the hydraulic system 240. In S605, the dumping controller 132 filters out agitation noise. In S607, the dumping controller 132 filters out the resonant frequency of the wheel loader machine 102. In S609, the dumping controller 132 determines the weight of the material in the bucket 118 based on the hydraulic system pressure and the removal of noise caused by agitation noise and the resonant frequency of the wheel loader machine 102.

[0058] In some embodiments, different agitation modes can be selected depending on the type of material being processed. The type of material can be characterized by particle size criteria and can include coarse, medium, fine, and powdered materials. Other finer particle size categories are also possible. Thresholds, such as agitation thresholds and final thresholds, can also differ for different types of materials.

[0059] For example, combined together, Figures 7 to 8 Disclosed is how the dump controller 132 induces agitation in a manner suitable for the material size in the bucket 118 of the wheel loader machine 102, based on the material type input 205 selected by the operator on the display device. Figure 7 In S701, the dump controller 132 checks whether coarse material is selected for material type input 205. If not ("No"), the process proceeds forward through A. Figure 8 .exist Figure 8 In the middle, the dump controller 132 checks whether medium-grained material is selected for material type input 205. If not, ("No"), the process proceeds forward through B to... Figure 9 .exist Figure 9 In the middle, the dump controller 132 checks whether fine-grained material is selected for material type input 205. If not ("No"), the process proceeds forward through C. Figure 10 .exist Figure 10 In the process, the dump controller 132 checks whether powder material has been selected for material type input 205. If not ("No"), it provides a message to the operator to select the material type.

[0060] Figure 7 This is a flowchart of a method for bucket agitation in the case of coarse-grained materials. In S701, the dumping controller 132 detects whether the material type input to the material type input 205 is coarse-grained. In S703, when the material is coarse-grained (yes in S701), a dumping process with agitation is executed according to the initial agitation pattern of the coarse-grained material. If the material is not coarse-grained (no in S701), the process moves via A... Figure 8 The agitation mode for coarse materials may include vigorous shaking of the bucket 118 at high amplitude, followed by lower amplitude and increased shaking frequency. In S705, the weight of the material is checked to determine whether the remaining weight of the coarse material in the bucket 118 is less than an agitation threshold. When the remaining weight of the coarse material is less than the agitation threshold (yes in S705), the agitation mode may be adjusted or maintained in S707. Adjustment of the agitation mode may include adjusting the duration of the agitation mode application. The agitation mode may be adjusted by changing the amplitude and / or frequency of the signal waveform, or by replacing the signal shape with a new signal shape. When the remaining weight of the material reaches the target weight (yes in S713), no further automatic unloading is required, and the unloading process ends.

[0061] In S709, a dumping with agitation can be performed using an optional adjusted agitation mode or an agitation mode maintained by a previous step (e.g., S703).

[0062] In S711, the dumping controller 132 checks whether the remaining weight of the coarse material in the bucket 118 is less than a final threshold. If the remaining weight of the coarse material is still greater than the final threshold (no in S711), in S707, the agitation mode is optionally adjusted or maintained again, and the dumping process with agitation S709 is executed again using the agitation mode. The process of adjusting or maintaining the agitation mode S707 and the dumping process with agitation S709 are repeated until the remaining weight of the coarse material is less than the target weight (above the zero tolerance of the target weight) and within the final threshold (yes in S711).

[0063] Figure 8This is a flowchart of a bucket agitation method for medium-grained materials. In S801, the dump controller 132 determines whether the material type input to the material type input 205 is medium-grained. Medium-grained materials may require less tilt adjustment and a smaller agitation amplitude than coarse-grained materials. In S803, when the material type is medium-grained (yes in S801), a dumping process with agitation is performed according to the initial agitation pattern for medium-grained materials. The agitation pattern for medium-grained materials may include violently shaking the bucket 118 with an average amplitude, followed by a lower amplitude and an increased shaking frequency. In S805, the weight of the medium-grained material is checked to determine whether the remaining weight of the medium-grained material in the bucket 118 is less than an agitation threshold. When the remaining weight of the medium-grained material is less than the agitation threshold (yes in S805), in S807, the agitation pattern may be maintained or adjusted. Adjustment of the agitation pattern may include adjusting the duration of the applied agitation pattern. The agitation mode can also be adjusted by changing the amplitude and / or frequency of the signal waveform, or by replacing the signal shape with a new signal shape. When the remaining weight of the material reaches the target weight (yes in S813), no further automatic unloading is required, and the unloading process ends.

[0064] In S809, a dumping with agitation can be performed using an optional adjusted agitation mode or an agitation mode maintained by a previous step (e.g., by S803).

[0065] In S811, the dumping controller 132 checks whether the remaining weight of the material in the bucket 118 is less than a final threshold. If the remaining weight of the material is still greater than the final threshold (no in S811), the agitation mode can be optionally adjusted or maintained again in S807, and dumping with agitation S809 may be performed again using the adjusted agitation mode. The process of adjusting or maintaining the agitation mode S807 and dumping with agitation S809 is repeated until the remaining weight of the material is less than the target weight (above the zero tolerance of the target weight) and within the final threshold (yes in S811).

[0066] Figure 9This is a flowchart of a method for bucket agitation in the case of fine-grained materials. Fine-grained materials may require smaller tilt angle adjustments and smaller agitation amplitudes than medium-grained materials. In S901, the dump controller 132 determines whether the material type input to the material type input 205 is fine-grained. In S903, when the material type is fine-grained (yes in S901), a dumping process with agitation is performed according to the initial pattern for fine-grained materials. The agitation pattern for fine-grained materials may include violently shaking the bucket 118 with an average amplitude, followed by lower amplitude and increased shaking frequency. In S905, the weight of the fine-grained material is checked to determine whether the remaining weight of the fine-grained material in the bucket 118 is less than an agitation threshold. When the remaining weight of the fine-grained material is less than the agitation threshold (yes in S905), in S907, the agitation pattern may be maintained or adjusted. Adjustment of the agitation pattern may include adjusting the duration of the applied agitation pattern. The agitation mode can be adjusted by changing the amplitude and / or frequency of the signal waveform, or by replacing the signal shape with a new signal shape. When the remaining weight of the material reaches the target weight (as in S913), no further automatic unloading is required, and the unloading process ends.

[0067] In S909, a dumping with agitation can be performed using an optional adjusted agitation mode or an agitation mode maintained by a previous step (e.g., by S903).

[0068] In S911, the dumping controller 132 checks whether the remaining weight of the fine material in the bucket 118 is less than a final threshold. If the remaining weight of the fine material is still greater than the final threshold (no in S911), in S907, the agitation mode is optionally adjusted or maintained again, and the dumping process with agitation S909 is executed again using the adjusted or maintained agitation mode. The process of adjusting or maintaining the agitation mode S907 and the dumping process with agitation S909 are repeated until the remaining weight of the material is less than the target weight (above the zero tolerance of the target weight) and within the final threshold (yes in S911).

[0069] Figure 10This is a flowchart of a method for agitating the bucket in the case of powder materials. The powder material may be viscous and may not overflow uniformly and consistently. In S1001, the dumping controller 132 determines whether the material type input to the material type input 205 is a powder material. In S1003, when the material type is powder (yes in S1001), a dumping process with agitation is performed according to the initial agitation pattern of the powder material. The agitation pattern for the powder material may include violently shaking the bucket 118 with an average amplitude, followed by a lower amplitude and an increased shaking frequency. In S1005, the weight of the powder material is checked to determine whether the remaining weight of the powder material in the bucket 118 is less than an agitation threshold. When the remaining weight of the powder material is less than the agitation threshold (yes in S1005), in S1007, the agitation pattern may be maintained or optionally adjusted. Adjustment of the agitation pattern may include adjusting the duration of the applied agitation pattern. The agitation mode can be adjusted by changing the amplitude and / or frequency of the signal waveform, or by replacing the signal shape with a new signal shape. When the remaining weight of the material reaches the target weight (yes in S1013), no further automatic unloading is required, and the unloading process ends.

[0070] In S1009, a dumping with agitation can be performed using an optional adjusted agitation mode or an agitation mode maintained by a previous step (e.g., by S1003).

[0071] In S1011, the dumping controller 132 checks whether the remaining weight of the powder material in the bucket 118 is less than a final threshold. If the remaining weight of the powder material is still greater than the final threshold (no in S1011), in S1007, the agitation mode is optionally adjusted or maintained again, and the dumping process with agitation S1009 is executed again using the adjusted or maintained agitation mode. The process of optionally adjusting or maintaining the agitation mode S1007 and the dumping process with agitation S1009 are repeated until the remaining weight of the powder material is less than the target weight (above the zero tolerance of the target weight) and within the final threshold (yes in S1011).

[0072] Figure 11 This is a flowchart illustrating the adjustment of the coarse agitation mode and duration in the bucket agitation method of S707. As described above, the agitation mode can be adjusted by adjusting the amplitude, frequency, or waveform. Furthermore, the duration of the agitation mode can be adjusted. For example, in the case of coarse-grained materials, in S1101, the agitation mode can be adjusted by changing the amplitude and / or frequency percentage C% and / or by changing the waveform. For example, changes in the waveform may include changes from a high-frequency, low-amplitude buzzing motion to a low-frequency, high-amplitude bouncing motion, or other combinations thereof.

[0073] Figure 12This is a flowchart illustrating the adjustment of the medium agitation mode and duration in the bucket agitation method of S807. In the case of medium-grained materials, as an example, in S1201, the agitation mode can be adjusted by changing the amplitude and / or frequency by a percentage M% different from the percentage C%, and / or by changing the waveform. For example, waveform changes can include a change from a high-frequency, low-amplitude buzzing motion to a low-frequency, high-amplitude bouncing motion, or other combinations thereof.

[0074] Figure 13 This is a flowchart illustrating the adjustment of the fine agitation mode and duration in the bucket agitation method of S907. In the case of fine-grained materials, such as in S1301, the agitation mode can be adjusted by changing the amplitude and / or frequency by a percentage F% different from the percentages M% and C% and / or by changing the waveform. For example, waveform changes can include a change from a high-frequency, low-amplitude buzzing motion to a low-frequency, high-amplitude bouncing motion, or other combinations thereof.

[0075] Figure 14 This is a flowchart illustrating the adjustment of the powder agitation mode and duration in the bucket agitation method of S1007. In the case of powder materials, as an example, in S1401, the agitation mode can be adjusted by changing the mode waveform and duration. For example, the waveform change may include a change from a high-frequency, low-amplitude buzzing motion to a low-frequency, high-amplitude bouncing motion, or other combinations thereof.

[0076] To further improve the accuracy of dumping volumes for various types of materials, machine learning can be used to model dumping processes with agitation from one or more perspectives. In one viewpoint, machine learning can be used to model the amount of material spilled during bucket dumping based on features of the dumping process that include agitation patterns. In another viewpoint, machine learning can be used to simulate the regulation of agitation patterns, where the agitation patterns are sequences.

[0077] Machine learning can be performed using a general-purpose computer, preferably equipped with circuitry for performing the mathematical functions required for machine learning, such as a graphics processing unit (GPU) or other dedicated processor. Alternatively, machine learning can be performed in a cloud service that provides support for machine learning algorithms. Machine learning can use statistical models, such as Bayesian probabilities, for ease of training. Machine learning can use simple single-layer neural networks for adaptive learning (iterative, online learning). Machine learning can use time series models (e.g., recurrent neural networks) to learn sequences of dumping inspection steps with agitation for a specific type of material.

[0078] Figure 15This is a diagram of the architecture of a neural network 1503 used to adaptively determine material weight changes based on agitation patterns. In one embodiment, machine learning can be used to improve dumping, agitation, and inspection to dump a certain amount of material. The machine learning model can be used to improve the accuracy of the amount of material dumped (the change in material weight due to dumping) in the agitation pattern, including amplitude adjustment, selection of the fluctuation pattern, a certain type of material, bucket tilt angle, bucket tilt speed, and boom height. The bucket tilt angle can be the maximum tilt angle of the bucket's dumping motion in a single dumping action. The bucket tilt speed can be the tilt speed relative to the tilt angle. The boom height can be the length extended by the boom cylinder 124 during the dumping motion.

[0079] refer to Figure 15 In a non-limiting example, the neural network 1503 may be configured with neural network input 1501, which may include material type 1511, the amount of material remaining in the bucket 1513, tilt angle 1515 for tilting motion, tilt speed 1517 for tilting motion, boom position 1519, agitation pattern waveform shape 1521, pattern amplitude 1523, and desired weight change 1525. The output of the neural network 1503 may be configured with a neural network output 1507 that changes the material weight in a single unloading motion. The neural network output 1507 is not limited to... Figure 15 The node layer shown can take any of several different forms. For example, a change in weight can be represented by several nodes, where each node is a range of weights, such as range A1531, range B1533, or it can be several nodes representing binary values ​​of the amount or percentage of weight change. The neural network 1503 can be a single-layer neural network, or it can include at least one optional hidden layer 1505. The neural network 1503 can be adaptive and can learn changes in material weight for different types of material agitation patterns. For adaptability (i.e., online training), the stochastic gradient descent algorithm can be used to train the neural network 1503.

[0080] Figure 16 This is a diagram illustrating the architecture of a recurrent neural network (RNN) 1605 for determining a churning pattern as a sequence according to an embodiment of the present invention. In one or more non-limiting embodiments, the churning pattern may be in the form of a sequence, such as a time series, wherein adjustments to the churning pattern can be learned as a correction sequence. The sequential churning pattern may be a waveform that varies over time and depends on characteristics such as the material type and the amount of material remaining in the bucket.

[0081] In one or more embodiments, a recurrent neural network 1605 may be trained to learn the relationship between material type, the amount of material remaining in the bucket, and a previous agitation pattern sequence as input and a regulated agitation pattern sequence as output.

[0082] The Recurrent Neural Network 1605 can be configured to learn time-series data and can be configured using Long Short-Term Memory (LSTM) units. An RNN1605 using LSTM units can be trained in a supervised manner on a set of training sequences, using optimization algorithms such as gradient descent combined with backpropagation to compute the gradients needed during the optimization process, so that each weight of the LSTM network changes proportionally to the derivative of the error (in the output layer of the LSTM network) with respect to the corresponding weight.

[0083] refer to Figure 16 An exemplary recurrent neural network 1605 may be configured with an RNN input 1601 of material type 1611, remaining quantity 1613, and a previous agitation pattern sequence 1615. The RNN output 1607 of the recurrent neural network 1605 may be configured to have an output of a regulated agitation pattern sequence 1631. At least one hidden layer 1603 with feedback connections is included between the RNN input 1601 and the RNN output 1607. The previous agitation pattern sequence may be a partial input with a window size, or it may be an input as a time step, wherein each time step is input sequentially one at a time. The regulated agitation pattern sequence may be output synchronously with the input of the previous agitation pattern sequence.

[0084] In an alternative embodiment, the RNN input to the recurrent neural network 1605 may consist of a sequence of the remaining amount of material of the material type, and the RNN output 1607 may be a stirring pattern corresponding to the remaining amount of material.

[0085] While various aspects of the invention have been specifically shown and described with reference to the foregoing embodiments, those skilled in the art will understand that various additional embodiments can be contemplated through modifications to the disclosed machines, components, systems, and methods without departing from the spirit and scope of the disclosure. These embodiments should be understood to fall within the scope of the invention as defined by the claims and any equivalents.

Claims

1. A method for controlling the movement of a bucket, the bucket having at least one electrically controlled actuator, the electrically controlled actuator being controlled by a control signal from a computer controller upon receiving a sensor signal from at least one sensor associated with the bucket, the method comprising: Target weight of received granular or powdered material; Receive a disturbance pattern of signal waveform shape having one or more frequencies and one or more amplitudes within a time period; The weight of the granular or powdered material in the bucket is detected via the sensor signal and is within the target weight of the final bucket load; The weight of granular or powdered materials is measured by sensor signals and the remaining amount is updated to achieve the target weight. Depending on the agitation pattern, some granular or powdery material overflows from the bucket; While the material is being overflowed from the bucket, the bucket is shaken according to the agitation mode to agitate the granular or powdery material and update the remaining amount. as well as Perform overflow and shake according to the agitation mode until the remaining amount is equal to or less than the target weight.

2. The method according to claim 1, wherein the electro-hydraulic actuator is an electro-hydraulic actuator; The agitation pattern of shaking the bucket includes: The agitation mode is applied via the control signal; Detect the pressure in the electro-hydraulic actuator; The pressure signal for the pressure in the electro-hydraulic actuator is received via the at least one sensor; Filtering out agitation noise from the pressure signal; and The remaining amount is determined based on the filtered pressure signal.

3. The method according to claim 1, further comprising: The type of particulate or powder material received; as well as The agitation mode is determined based on the type of particulate or powder material.

4. The method according to claim 1, further comprising: The agitation mode is adjusted by changing the shape of the signal waveform of the agitation mode.

5. The method according to claim 1, wherein The agitation pattern of the bucket involves performing one or more light, tumbling motions followed by a rapid buzzing motion.

6. The method according to claim 1, wherein The agitation pattern of the bucket includes the initial portion of the large overflow performed by the bucket.

7. The method according to claim 3, wherein The determination of the agitation pattern is performed using a neural network having multiple inputs, including: The type of granular or powdered material, The remaining amount of the granular or powdered material in the bucket, and Stirring mode, and The weight change of the granular or powdered material in the bucket is provided as the output of the neural network.

8. The method according to claim 4, wherein A neural network is used to perform the regulation of the agitation pattern, the neural network having a sequence input including past agitation patterns and a sequence output of the regulated agitation pattern.

9. A construction vehicle, comprising: Electro-hydraulic system; The bucket is operated by the electro-hydraulic system; as well as An automatic unloading system, including an agitation system, the automatic unloading system comprising: An input / output device configured to receive input control parameters and output bucket status information; as well as The controller is configured as follows: Target weight of received granular or powdered material; The system receives multiple hydraulic inputs from the electro-hydraulic system and determines the weight of the granular or powdered material in the bucket based on at least one hydraulic input. Generate control signals for controlling the operation of the bucket in the electro-hydraulic system, and When the controller generates a control signal for the unloading motion of the bucket, the agitation system is automatically controlled to generate a rocking motion of the bucket, thereby overflowing granular or powdery material according to the agitation mode until the weight of the granular or powdery material in the bucket is equal to or less than the target weight.

10. The construction vehicle according to claim 9, wherein The controller includes a memory for storing multiple agitation patterns. The agitation mode mentioned above is a ripple mode.

11. The construction vehicle according to claim 9, wherein The input / output device includes an input for the type of granular or powdered material, and The controller includes a memory for storing multiple agitation modes, each based on a corresponding type of the granular or powdered material.

12. The construction vehicle according to claim 10, wherein The agitation mode includes a mode that generates a control signal to produce a slight bounce in the bucket, followed by a buzzing motion of the bucket.

13. The construction vehicle according to claim 10, wherein The controller is configured to adjust at least one of the agitation modes by changing the waveform shape of at least one of the agitation modes, and The waveform shape is one or more of a sine wave, a sawtooth shape, and a square wave.

14. The construction vehicle according to claim 10, wherein The controller is configured to adjust at least one of the agitation modes by changing one or more of the amplitude and frequency of the waveform shape of at least one of the agitation modes.

15. The construction vehicle according to claim 10, wherein The controller is configured to adjust at least one of the agitation modes by replacing at least one of the agitation modes with a new agitation mode.

16. The construction vehicle according to claim 10, wherein The controller is configured to adjust at least one of the agitation modes by changing the duration of the control signal applied for at least one of the agitation modes.

17. The construction vehicle according to claim 9, wherein The controller is configured to periodically weigh the granular or powdery material contained in the bucket in order to determine the weight of the granular or powdery material in the bucket based on at least one of the hydraulic pressures in the electro-hydraulic system and by removing noise caused by agitation according to the agitation mode and at least one construction vehicle resonant frequency.

18. A wheel loader machine, comprising: A bucket, configured to hold a predetermined load of granular or powdered material; A hydraulic system having at least one electro-hydraulic actuator to move and rock the bucket within a tilt angle range; A hydraulic sensor configured to detect at least one hydraulic pressure in the hydraulic system; An input / output interface is configured to receive input parameters and output status information of the bucket, the input parameters including a target weight of the granular or powdered material, and the status information including the weight of the granular or powdered material in the bucket determined based on at least one hydraulic pressure detected by the hydraulic sensor. as well as An automatic unloading system, including an agitation system, the automatic unloading system comprising: A controller is configured to control the hydraulic system to tilt the bucket to a predetermined angle and to agitate the bucket according to a stirring mode until the weight of the granular or powdery material in the bucket is equal to or less than the target weight of the granular or powdery material.

19. The wheel loader machine according to claim 18, wherein The input parameters include the agitation mode, and The agitation mode is selected from a plurality of agitation modes stored in the memory of the controller.

20. The wheel loader machine according to claim 18, wherein... The agitation mode generates a control signal to produce a buzzing motion of the bucket, followed by a light flicking of the bucket in a single direction.

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