Virtual boundary system for work machine
By integrating multiple sensors and control modules into the operating machine, the virtual boundary system solves the problem of insufficient three-dimensional boundary constraints in the existing technology, realizes precise monitoring of the position and orientation of the operating tool, and reduces operational risks and the probability of damage.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- Filing Date
- 2021-09-24
- Publication Date
- 2026-05-15
AI Technical Summary
Existing technologies have failed to effectively address the three-dimensional boundary constraints of operating machines when approaching obstacles and hazards, especially considering complex three-dimensional boundaries and the three-dimensional orientation of operating tools, leading to increased operational risks and insufficient accuracy.
The system employs an instrument system with multiple position and orientation sensors and a tilting and rotating system, combined with a control module, to receive the 3D model and virtual boundary input of the working tool and automatically prevent the working tool from crossing the virtual boundary.
It enables precise monitoring of the position and orientation of the work tool in three-dimensional space, automatically prevents it from approaching obstacles, reduces operational risks and the probability of damage, and improves work accuracy.
Smart Images
Figure CN116234962B_ABST
Abstract
Description
Technical Field
[0001] This disclosure generally relates to working machines, and more specifically to methods and systems for providing virtual boundaries for working machines with working tools. Background Technology
[0002] Excavators and other similar work machines must frequently operate in close proximity to obstacles and hazards such as walls, power lines, roads, and buried utility installations. These machines, which can include any number of construction, excavating, agricultural, and industrial work machines (including but not limited to excavators, bulldozers, tractors, etc.), typically have work tools with a wide range of motion that could come into contact with these hazards. The need to work in confined areas increases the risk of damage to the machine or its surrounding environment. Furthermore, the constant need to restrict the machine's movement also places stress on the operator.
[0003] Existing technologies have failed to adequately address this problem. While systems such as those disclosed in U.S. Patent No. 9,725,874 to Meguriya et al. provide some form of automated motion constraint, these systems focus on automatically creating a level surface at a specific slope. Furthermore, they do not take into account the three-dimensional orientation of the working tool or complex three-dimensional boundaries. Additionally, previous boundary systems require the assumption that the working tool is spherical, which limits accuracy.
[0004] Therefore, a machine with a more refined boundary system is needed. Summary of the Invention
[0005] According to one aspect of this disclosure, a machine with a working tool is disclosed. The machine includes a frame; a plurality of traction devices supporting the frame; an engine mounted to the frame; an operator's cab mounted to the frame; a tool system configured to move the working tool to a desired position in three dimensions and having a plurality of position sensors; a tilt-rotation system for moving the working tool to a desired orientation in three dimensions and having a plurality of orientation sensors; an operator interface configured to receive boundary input and tool control input; and a control module. The control module is configured to receive a three-dimensional model of the working tool, receive boundary input defining a virtual boundary from the operator interface, receive signals from the plurality of position sensors and the plurality of orientation sensors, receive tool control input from the operator interface, determine the position and orientation of the working tool based on the signals and the model, determine whether the working tool is approaching the virtual boundary based on the position and orientation of the working tool, the boundary input, and the tool control input, and automatically prevent the working tool from crossing the virtual boundary.
[0006] According to another aspect of this disclosure, a virtual boundary system for a machine with a working tool is disclosed. The system includes a tool system configured to move the working tool to a desired position in three dimensions and having a plurality of position sensors; a tilt-rotation system for moving the working tool to a desired orientation in three dimensions and having a plurality of orientation sensors; an operator interface configured to receive boundary input and tool control input; and a control module. The control module is configured to receive a three-dimensional model of the working tool, receive boundary input defining a virtual boundary from the operator interface, receive signals from the plurality of position sensors and the plurality of orientation sensors, receive tool control input from the operator interface, determine the position and orientation of the working tool based on the signals and the model, determine whether the working tool is approaching the virtual boundary based on the position and orientation of the working tool, the boundary input, and the tool control input, and automatically prevent the working tool from crossing the virtual boundary.
[0007] According to another aspect of this disclosure, a method for controlling a work tool is disclosed. The method includes receiving a three-dimensional model of the work tool, receiving boundary input defining a virtual boundary, receiving signals from multiple position sensors and multiple orientation sensors, receiving tool control input from an operator interface, determining the position and orientation of the work tool based on the signals and the model, determining whether the work tool is approaching the virtual boundary based on the position and orientation of the work tool, the boundary input, and the tool control input, and automatically preventing the work tool from crossing the virtual boundary.
[0008] These and other aspects and features of this disclosure will be more readily understood after reading the following detailed description in conjunction with the accompanying drawings. Attached Figure Description
[0009] Figure 1 This is a perspective view of the machine in operation according to aspects of this disclosure.
[0010] Figure 2 This is a block diagram of a virtual boundary system according to one aspect of this disclosure.
[0011] Figure 3 This is a close-up view of the excavator's working tools and virtual boundary according to one aspect of this disclosure.
[0012] Figure 4 It is a side view of the excavator and virtual boundary according to one aspect of this disclosure.
[0013] Figure 5 This is a side view of the operating machine and virtual boundary according to one aspect of this disclosure.
[0014] Figure 6 This is a top view of the operating machine and virtual boundary according to one aspect of this disclosure.
[0015] Figure 7 It is a perspective view of the operating machine and virtual boundary according to one aspect of this disclosure.
[0016] Figure 8 This is a top view of the operating machine and virtual boundary according to one aspect of this disclosure.
[0017] Figure 9 This is a side view of the operating machine and virtual boundary according to one aspect of this disclosure.
[0018] Figure 10 It is a perspective view of the operating machine and virtual boundary according to one aspect of this disclosure.
[0019] Figure 11 This is a flowchart of a method for restricting the movement of a work tool according to one aspect of this disclosure. Detailed Implementation
[0020] Now refer to the attached diagram, and specifically refer to... Figure 1 The exemplary operating machine according to this disclosure is referred to by reference numeral 100. Specifically, Figure 1 An excavator is shown, but the work machine 100 could also be other types of construction or excavation machinery, such as a backhoe, front shovel, wheel loader, or another similar machine, as well as a material handling machine. Figure 1 As shown, the machine 100 includes a frame 110 having a lower section 112 and an upper section 114. The lower section 112 is supported by a ground engagement device 116, which may be tracks, wheels, or the like. An engine 118 and an operator's cab 120 are mounted on the upper section 114.
[0021] Additionally, machine 100 has a tool system 130 configured to move working tool 150 to perform tasks of machine 100. Tool system 130 may include a boom 132 and a stick 134. Boom 132 has a first end 133 connected to an upper section 114 of frame 110 and is vertically pivotable relative to frame 100. A second end 135 of boom 132 is connected to stick 134, which is also vertically pivotable. Boom 132 and stick 134 may be positioned by a hydraulic cylinder 136 or any other mechanism capable of moving parts as needed. Tool system 130 may also include a swing system 140 (not shown) that allows tool system 130 to rotate about frame 110. Swing system 140 is configured to rotate the upper section 114 of frame 110 relative to lower section 112. This allows lower section 112 of frame 110 to maintain a stable base while upper section 114 rotates tool system 130 to a desired angle. The swing system 140 can also be operated by hydraulic components 136.
[0022] The tool system 130 also includes multiple position sensors 230. Position sensors 230 may include displacement sensors on hydraulic cylinders, angle sensors at pivot joints, inclinometers, gyroscope sensors, tilt sensors, global reference sensors, or any other sensors that may help determine the position of the working tool. Position sensors 230 provide signals to control module 210 (see...). Figure 2 ).
[0023] The working tool 150 is attached via a tilt-rotation system 160 to the end of the stick 134 furthest from the boom 132, the tilt-rotation system being configured to allow the working tool 150 to tilt and rotate in multiple dimensions. The working tool 150 shown is a bucket, but may alternatively be any device for performing a specific task, including but not limited to forks, blades, shovels, or any other task-performing device. The tilt-rotation system 160 also includes a plurality of orientation sensors 260, including at least a rotation sensor 252 and a tilt sensor 254. The orientation sensors 260 may include displacement sensors on hydraulic cylinders, angle sensors at pivot joints, inclinometers, gyroscope sensors, tilt sensors, or any other sensors that may help determine the orientation of the working tool 150.
[0024] The movement of the appliance system is controlled by the control module 210 based on appliance control inputs 240 from the operator in the operator's room 120 via the operator interface 220. The appliance control inputs 240 may be provided by a joystick, button, touch interface, or any other device effective for this purpose.
[0025] The controls and orientation sensor 260 of the tilt-rotation system 160 are directly integrated into the same control module 210 as the tool system 130. Therefore, the orientation of the work tool 150 is controlled by the tilt-rotation system 160 via inputs to the operator interface 220 and the tool control input 240 in the control module 210. In some other systems, similar tilt-rotation systems include a separate control module that interfaces with the primary machine control module and is the means of transmitting lever commands. If such a separate control module fails, the machine may become inoperable because it will be unable to read and transmit lever commands. Integrating the tilt-rotation system 160 into the control module 210 allows direct access to sensor information, prevents delays, and allows for more efficient error diagnosis. In particular, integration allows for partial shutdown and diagnostics in the event of a partial failure rather than a complete machine failure.
[0026] The tool system 130 and the tilt-rotor system 160 together allow the working tool 150 to move to any position and orientation within a three-dimensional range. However, in many applications, certain portions of this range should be avoided to prevent damage to the area or to prevent damage from obstacles and hazards within the area, or for other reasons. The virtual boundary system 200 can be used to automatically limit the movement of the working tool beyond a desired range having at least one virtual boundary 300. Figure 2 As shown, the virtual boundary system 200 includes a position sensor 230 of the appliance system 130, an orientation sensor 260 of the tilt and rotation system 160, an operator interface 220, and a control module 210.
[0027] Before starting work, the control module 210 receives a 3D model of the work tool 150. The model includes the dimensions of the work tool 150, including details of its external shape. Figure 3 As shown, this allows the system to determine whether the working tool 150 is approaching the virtual boundary 300 based on its actual shape rather than an approximation. If the working tool 150 is a bucket or similar tool with internal space, the model does not need to include the internal shape. In the bucket example, the system can determine whether the corner teeth of the shovel or the rear of the bucket is approaching the virtual boundary.
[0028] The control module 210 also receives a boundary input 250 defining the virtual boundary 300. The boundary input 250 can be provided via the operator interface 220. The virtual boundary 300 is configured as a plane, which can be oriented in various ways. A horizontal plane can serve as a lower limit below the machine 100, such as... Figure 4 As shown, or above machine 100 as the upper limit ( Figure 5 The vertical plane can be parallel to the boom and stick of machine 100 to prevent lateral movement. Figure 6 ), can be located in front of machine 100 ( Figure 7Or at any angle between the sidewall and the front wall, one such embodiment is in Figure 8 As shown in the image. Figure 9 As shown, the vertical plane can also be used to protect operator's compartment 120. Finally, as... Figure 10 As shown, the virtual boundary 300 can be a plane that is neither vertical nor horizontal, but rather forms a slope. It is conceivable that other boundaries 300 may include curved shapes or other complex shapes.
[0029] The virtual boundary 300 can be either manually entered, including measured values of offset, slope, and lateral slope, or programmed into the control module 210 as a boundary input by placing the bucket at a series of points and setting a plane relative to those locations. Of course, other methods can be used to provide boundary parameters. The boundary 300 can be indicated relative to the machine 100 or indicated as a global reference. The global reference can use global position and orientation from GNSS, or less information, such as altitude only or heading only, such as from a compass. Multiple boundaries can be entered to fully define the work area.
[0030] When machine 100 is operating, control module 210 receives signals from multiple position sensors 230 and multiple orientation sensors 260. These signals allow control module 210 to determine the precise position and orientation of working tool 150 in three-dimensional space. Combined with a model of working tool 150, this makes it possible to have a precise understanding of the position of all edges and ends of working tool 150.
[0031] The control module 210 also receives appliance control inputs 240 from the operator interface 220. These inputs indicate actions taken by the operator instructing the appliance system 130 and the tilt-rotation system 160.
[0032] Next, the control module determines whether the work tool 150 is approaching the virtual boundary 300 based on the determined position and orientation of the work tool 150, the boundary 250, and the appliance control input 240.
[0033] Finally, the work tool 150 is automatically prevented from crossing the virtual boundary 300. This is achieved by stopping any movement of the appliance system 130 or the tilt-rotation system 160, despite any further appliance control inputs 240 from the operator in that direction. Appliance control inputs 240 indicating movement away from the virtual boundary 300 are unaffected.
[0034] The virtual boundary system 200 may also include an alarm if the work tool 150 approaches within a threshold distance of the virtual boundary 300. This alarm may be a visual or audible indicator in the operator's room 120.
[0035] Industrial applicability
[0036] For example, excavators and other earthmoving and construction machinery must often operate in close proximity to obstacles and hazards such as walls, power lines, roads, and buried utility installations. The need to work in confined areas places stress on operators, who must constantly monitor the machine's movement. Furthermore, these conditions increase the risk of damage to the machine, its surroundings, and even bystanders. Virtual boundary systems 200 can be useful in any application where working tools must operate in confined spaces. This could include construction, mining, agriculture, and similar industries.
[0037] Virtual boundary system 200 uses the following method 400, such as Figure 11 As shown in the diagram. Before commencing work, control module 210 receives a three-dimensional model (box 410) of the work tool 150. The model includes the dimensions of the work tool, including details of its shape. This allows the system to determine whether the work tool is approaching an obstacle based on its actual shape and three-dimensional orientation, rather than approximations.
[0038] The control module 210 also receives boundary input (box 420) defining the virtual boundary 300 from the operator interface. The virtual boundary 300 can be defined by offsets, slopes, and lateral slopes manually entered as measurements, or by placing the work tool at several points on a plane. The measurements can be defined relative to machine 100 or as a global reference. The virtual boundary 300 can have a planar shape.
[0039] When machine 100 is in operation, control module 210 receives signals from multiple position sensors 230 and multiple orientation sensors 260 (box 430). As shown in box (440), control module 210 also receives appliance control inputs from operator interface 220. These inputs indicate actions taken by operator-instructed appliance system 130 and tilt-rotation system 160.
[0040] Based on the signals, control module 210 determines the position and orientation of the work tool 150 in three dimensions (box 450). Next, as shown in box 460, the control module determines whether the work tool 150 is approaching the virtual boundary 300 based on the position and orientation of the work tool 150 (as determined in box 450) and boundary and tool control inputs. If the work tool is approaching the virtual boundary (box 470), the work tool 150 is automatically prevented from crossing the virtual boundary 300, as shown in box 480. This is achieved by stopping any movement of the tool system 130 or the tilt-rotation system 160, despite any further operator input in that direction. On the other hand, if the work tool is not approaching the virtual boundary, machine 100 continues normal operation (box 490), and operator inputs indicating movement away from the virtual boundary 300 are unaffected.
[0041] Although the foregoing text has described in detail many different embodiments, it should be understood that the legitimate scope of protection is defined by the wording of the claims set forth at the end of this patent. The detailed descriptions are to be interpreted as exemplary only, and not every possible embodiment is described, as describing every possible embodiment would be impractical, if not impossible. Many alternative embodiments can be implemented using present technology or technology developed after the date of this patent application, which will still fall within the scope of the claims defining the scope of protection.
Claims
1. A machine (100), comprising: A working tool (150), the working tool including an edge and an end; A frame (110) having an upper segment (114) and a lower segment (112); Multiple traction devices (116) supporting the frame (110); An engine (118) is mounted to the frame (110); Operator's room (120) installed on the frame (110); An implement system (130) connected to the frame (110) includes a boom (132), a stick (134), and a swing system. The boom (132) has a first end (133) and a second end (135). The first end (133) of the boom (132) is connected to the upper section (114) of the frame (110), and the second end (135) of the boom (132) is connected to the stick (134). The boom (132) and the stick (134) are vertically pivotable. The swing system is configured to rotate the upper section (114) of the frame (110) relative to the lower section (112) to cause the implement system (130) to rotate about the frame (110). The implement system (130) is configured to move the working tool (150) to a desired position in three dimensions and has a plurality of position sensors (230). A tilt rotation system (160) is configured to move the working tool (150) to a desired orientation in three dimensions and has a plurality of orientation sensors (260); Operator interface (220), the operator interface being configured to receive boundary input (250) and appliance control input (240); as well as Control module (210), the control module being configured to: Receive the three-dimensional model of the working tool (150). Receive the boundary input (250) defining the virtual boundary (300) from the operator interface (220). Signals are received from the plurality of position sensors (230) and the plurality of orientation sensors (260). Receive the appliance control input (240) from the operator interface (220). The position and orientation of the working tool (150) are determined based on the signal and the model. Based on the position of the working tool (150), the boundary input (250), and the appliance control input (240), it is determined whether the working tool (150) is approaching the virtual boundary (300), and Automatically prevent the work tool (150) from crossing the virtual boundary (300); The working tool (150) is attached via the tilting rotation system (160) to the end of the stick (134) furthest from the boom (132); and the model includes details of the external shape of the working tool (150); The control module (210) is further configured to: It is also determined whether the work tool (150) is approaching the virtual boundary (300) based on the orientation and shape of the work tool (150), including the positions of all the edges and ends of the work tool (150).
2. The machine (100) according to claim 1, wherein the tilt rotation system (160) controls and sensors are directly integrated into the control module (210).
3. The machine (100) according to claim 1, wherein more than one virtual boundary (300) is defined.
4. The machine (100) according to claim 1, wherein the virtual boundary (300) is planar.
5. The machine (100) according to claim 1, wherein the virtual boundary (300) is defined by offset, slope and lateral slope.
6. The machine (100) according to claim 1, wherein the virtual boundary is defined relative to the machine.
7. The machine (100) according to claim 1, wherein the virtual boundary (300) is defined by a global reference.
8. A virtual boundary system (200) for a machine (100) having a working tool (150), wherein the working tool includes an edge and an end, the virtual boundary system (200) comprising: An implement system (130) including a boom (132) and a stick (134), the implement system (130) being configured to move the work tool (150) to a desired position in three dimensions and having a plurality of position sensors (230); A tilt rotation system (160) is configured to move the working tool (150) to a desired orientation in three dimensions and has a plurality of orientation sensors (260); Operator interface (220), the operator interface being configured to receive boundary input (250) and appliance control input (240); as well as Control module (210), the control module being configured to: Receive the three-dimensional model of the working tool (150). Receive the boundary input (250) defining the virtual boundary (300) from the operator interface (220). Signals are received from the plurality of position sensors (230) and the plurality of orientation sensors (260). Receive the appliance control input (240) from the operator interface (220). The position and orientation of the working tool (150) are determined based on the signal and the model. Based on the position of the working tool (150), the boundary input (250), and the appliance control input (240), it is determined whether the working tool (150) is approaching the virtual boundary (300), and Automatically prevent the work tool (150) from crossing the virtual boundary (300); The working tool (150) is attached via the tilting rotation system (160) to the end of the stick (134) furthest from the boom (132); and the model includes details of the external shape of the working tool (150); The control module (210) is further configured to: It is also determined whether the work tool (150) is approaching the virtual boundary (300) based on the orientation and shape of the work tool (150), including the positions of all the edges and ends of the work tool (150).
9. The system (200) according to claim 8, wherein the tilt rotation system (160) controls and sensors are directly integrated into the control module (210).
10. The system (200) of claim 8, wherein more than one virtual boundary (300) is defined.
11. The system (200) according to claim 8, wherein the virtual boundary (300) is planar.
12. The system (200) of claim 8, wherein the virtual boundary (300) is defined by offset, slope and lateral slope.
13. The system (200) of claim 8, wherein the virtual boundary is defined relative to the machine.
14. The system (200) of claim 8, wherein the virtual boundary (300) is defined by a global reference.
15. The system (200) of claim 8, wherein the plurality of orientation sensors (260) includes tilt sensors and rotation sensors.