Loading range and dumper matching system and method

Abstract

The invention relates to the technical field of engineering machinery, and discloses a loading range and dumper matching system and method.The system comprises a control panel, a main controller, an angle sensor, a first distance sensor and a second distance sensor; the control panel is used for displaying information of the main controller and transmitting a user instruction to the main controller for processing; the main controller is used for processing a user instruction, a signal of the angle sensor, a signal of the first distance sensor and a signal of the second distance sensor; the angle sensor is used for measuring a rotation angle and transmitting rotation angle data to the main controller; the first distance sensor is used for measuring the distance between the counterweight and the carriage, recording the distance as N1 and transmitting the value N1 to the main controller; the second distance sensor is used for measuring the distance between the front end of the crawler belt and the carriage, recording the distance as N2 and transmitting the numerical value N2 to the main controller. According to the invention, whether the farthest loading range of the excavator can reach the foremost end of the carriage of the dumper can be accurately calculated.

Description

Technical Field

[0001] The present invention relates to the technical field of engineering machinery, and in particular to a system and method for matching a loading range with a dump truck, and in particular to a system and method for matching a loading range with a dump truck of an excavator. Background Art

[0002] Whether the loading range of a large excavator matches the dump truck has a great impact on loading efficiency. For example, if a customer wants to maximize the full load rate of a dump truck, the excavator must be able to reach the front end of the vehicle compartment or even the front end of the cab roof when unloading. If this requirement cannot be met, the excavator operator needs to adjust the entire machine or the dump truck driver needs to move the truck, which wastes time and affects loading efficiency. Therefore, how to achieve accurate matching between the loading range of a large excavator and a dump truck is an important issue facing current technology.

[0003] Most existing technical solutions use laser radar in combination with a variety of sensors to obtain various information such as the position of the car, so as to match the car with the computer. This relies on a combination of multiple electronic devices, has high costs and low reliability. In addition, the accuracy is greatly affected by the environment and working conditions. Summary of the invention

[0004] In view of the deficiencies of the prior art, the present invention provides a loading range and dump truck matching system and method, which can accurately calculate whether the farthest loading range of the excavator can reach the front end of the dump truck compartment.

[0005] To achieve the above object, the present invention provides the following technical solutions:

[0006] In a first aspect, the present invention provides a system for matching a loading range with a dump truck, including a control panel, a main controller, an angle sensor, a first distance sensor, and a second distance sensor;

[0007] The control panel is used to display the information of the main controller and transmit the user instructions to the main controller for processing;

[0008] The main controller is used to process user instructions, signals from the angle sensor, signals from the first distance sensor, and signals from the second distance sensor;

[0009] The angle sensor is used to measure the rotation angle and transmit the rotation angle data to the main controller;

[0010] The first distance sensor is used to measure the distance between the counterweight and the carriage, record it as N1, and transmit the value N1 to the main controller;

[0011] The second distance sensor is used to measure the distance between the front end of the crawler track and the carriage, which is recorded as N2, and the value N2 is transmitted to the main controller.

[0012] In combination with the first aspect, further, the first distance sensor is arranged at the rear end of the counterweight, and the second distance sensor is arranged on the rotating platform.

[0013] In combination with the first aspect, further, when the angle sensor detects that the rotation angle is greater than 180 degrees, the first distance sensor is activated and transmits the distance N1 between the counterweight and the carriage to the main controller; when the angle sensor detects that the rotation angle is less than 180 degrees, the second distance sensor is activated and transmits the distance N2 between the front end of the belt and the carriage to the main controller;

[0014] In combination with the first aspect, further, the loading range and dump truck matching system of the present invention also includes a memory, which is used to receive and store data transmitted by the angle sensor, the first distance sensor and the second distance sensor; the angle sensor transmits the rotation angle data to the memory for storage; the distance N1 between the counterweight and the car body of the first distance sensor is transmitted to the memory for storage; the distance N2 between the front end of the track of the second distance sensor and the car body is transmitted to the memory for storage.

[0015] In a second aspect, the present invention proposes a method for matching a loading range with a dump truck, comprising:

[0016] Determine the maximum loading length Q and the carriage length L; if Q ≥ L, the loading range matches this type of dump truck; if Q < L, the loading range does not match this type of dump truck, and a solution needs to be found.

[0017] In combination with the second aspect, further, the solution includes any of the following methods:

[0018] Method 1: Cancel the reduction of N value and increase Q according to the actual loading angle;

[0019] Method 2: Match a smaller dump truck to reduce L;

[0020] Method 2: Increase Q by adjusting the parameter values ​​related to Q, including the distance AF from point A to point F, the horizontal distance G from the hinge point at the root of the boom to the center of rotation, the tooth tip radius r of the bucket, the rotation radius R of the whole machine, and the reserved safety distance N between the excavator and the carriage;

[0021] Point A is the hinge point at the root of the boom, and point F is the intersection of the horizontal line AF and the vertical line EF.

[0022] In combination with the second aspect, further, when the user cannot reach the farthest point of the carriage by operating the excavator, the user operates according to the following steps:

[0023] Step S1, the user operates the loading range matching button on the control panel;

[0024] Step S2, the control panel prompts the user to input the carriage length L, the carriage height H2 and the platform height, where the platform height is the distance between the dump truck horizontal plane and the excavator working plane;

[0025] Step S3, after the input is completed, continue to prompt the user to operate the excavator (about 10 minutes), continue to use the excavator to determine the operating rotation angle of the excavator to determine the distance between the excavator and the dump truck, and transmit the distance to the main controller;

[0026] Step S4, if the rotation operation is greater than or equal to 180 degrees, the main controller determines the size of the distance N1 and N between the counterweight and the carriage, and takes the minimum value to calculate Q; if Q ≥ L, the user is prompted to shorten the distance between the dump truck and the excavator by N1-N, and the program stops; if Q < L, the calculation makes N = N2, and the size of Q and L is re-compared: if the re-comparison result is Q ≥ L, the user is prompted to change to loading less than 180 degrees, if the re-comparison result is Q < L, the value of L is reduced until Q ≥ L, and the user is prompted to use a suitable carriage length value, if the user selects yes, the program stops, if the user selects no, the user is prompted to contact the service personnel, and the program stops;

[0027] Step S5, if the rotation operation is less than 180 degrees, as in step S4, different N values ​​are sequentially substituted to calculate the size of Q and L until Q ≥ L, and the user is recommended a suitable N value; if the N value is not suitable, different L values ​​are sequentially substituted until Q ≥ L, otherwise the user is prompted to contact the service personnel for resolution;

[0028] Among them, Q is the maximum loading length; N is the reserved safety distance between the excavator and the carriage; L is the length of the carriage; N1 is the distance between the counterweight and the carriage; N2 is the distance between the front end of the crawler and the carriage.

[0029] In combination with the second aspect, further, the calculation formula of the farthest loading length Q is:

[0030] ;

[0031] Among them, point A is the hinge point of the boom root, point B is the hinge point of the boom upper ear plate, point C is the hinge point of the boom cylinder on the boom, point D is the overlapping hinge point of the boom and the boom, point E is the overlapping hinge point of the boom and the bucket, and the line between the hinge points is the distance between the hinge points; point F is the intersection of the horizontal line AF and the vertical line EF, r is the tooth tip circle radius of the bucket, G is the horizontal distance from the boom root hinge point to the rotation center, R is the rotation radius of the whole machine, N is the reserved safety distance between the excavator and the carriage, L is the length of the carriage, H1 is the distance from the boom root hinge point to the ground, and H2 is the height of the carriage.

[0032] In a third aspect, the present invention provides an excavator, comprising the above-mentioned loading range and dump truck matching system.

[0033] Compared with the prior art, the present invention provides a system and method for matching a loading range with a dump truck, which has the following beneficial effects:

[0034] (1) The present invention uses a method combining the quantitative and variable key dimensions of the excavator to accurately calculate the farthest loading range. According to the calculation result of the farthest loading range, the parameters that need to be changed for vehicle-machine matching can be accurately found. Through theoretical calculation, it can be determined whether the farthest loading range of the excavator can reach the front end of the dump truck compartment, with high accuracy.

[0035] (2) The present invention can facilitate designers to verify the rationality of the structural dimension design when initially designing the working device, achieve the matching of the excavator and the dump truck, and improve work efficiency.

[0036] (3) When the market feedback mining scope is insufficient, the present invention does not need to redraw the model. It only needs to determine the values ​​of BC, L, and N to quickly verify the rationality of the design and provide a solution.

[0037] (4) The calculation method of the present invention can be implemented on a computer or by manual calculation, and has high flexibility. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 is a schematic diagram of a matching system of Example 1;

[0039] Figure 2 This is a calculation principle diagram of the matching method of Example 1. DETAILED DESCRIPTION

[0040] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0041] Unless otherwise specifically stated, the relative arrangement, numerical expressions and numerical values ​​of the parts and steps set forth in these embodiments do not limit the scope of the present invention. Meanwhile, it should be understood that, for ease of description, the sizes of the various parts shown in the accompanying drawings are not drawn according to actual proportional relationships. The technology, methods and equipment known to those of ordinary skill in the relevant art may not be discussed in detail, but in appropriate cases, the technology, methods and equipment should be considered as a part of the specification. In all examples shown and discussed here, any specific value should be interpreted as being merely exemplary, rather than as a limitation. Therefore, other examples of exemplary embodiments may also include different values. It should be noted that similar reference numerals and letters represent similar items in the following drawings, and therefore, once a certain item is defined in an accompanying drawing, it does not need to be further discussed in subsequent drawings.

[0042] In the description of the present application, it should be understood that the terms "center", "longitudinal", "lateral", "up", "down", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the protection content of the present invention.

[0043] Example 1

[0044] like Figure 1 As shown, the loading range and dump truck matching system of this embodiment includes a control panel, a main controller, an angle sensor, a first distance sensor and a second distance sensor; the control panel is used to display the information of the main controller and transmit the user command to the main controller for processing; the main controller is used to process the user command, the signal of the angle sensor, the signal of the first distance sensor and the signal of the second distance sensor; the angle sensor is used to measure the rotation angle and transmit the rotation angle data to the main controller; the first distance sensor is arranged at the rear end of the counterweight, and is used to measure the distance between the counterweight and the car body, recorded as N1, and the value N1 is transmitted to the main controller; the second distance sensor is arranged on the rotating platform, and is used to measure the distance between the front end of the crawler track and the car body, recorded as N2, and the value N2 is transmitted to the main controller.

[0045] In a specific implementation of the present embodiment, the loading range and dump truck matching system of the present embodiment also includes a memory, which is used to receive and store data transmitted by the angle sensor, the first distance sensor and the second distance sensor; the angle sensor transmits the rotation angle data to the memory for storage; the distance N1 between the counterweight and the car body of the first distance sensor is transmitted to the memory for storage; the distance N2 between the front end of the track of the second distance sensor and the car body is transmitted to the memory for storage.

[0046] When the angle sensor detects that the rotation angle is greater than 180 degrees, the first distance sensor is activated and transmits the distance N1 between the counterweight and the car body to the main controller and the memory; when the angle sensor detects that the rotation angle is less than 180 degrees, the second distance sensor is activated and transmits the distance N2 between the front end of the belt and the car body to the main controller and the memory.

[0047] The method for matching the loading range with the dump truck of this embodiment includes: judging the size of the farthest loading length Q and the car body length L; if Q≥L, the loading range matches the type of dump truck; if Q<L, the loading range does not match the type of dump truck, and a solution needs to be found.

[0048] In a specific implementation of this embodiment, if the loading range does not match the type of dump truck, the problem can be solved from three aspects: first, cancel the reduction of N value and increase Q according to the actual loading angle; second, match a smaller dump truck and reduce L; third, increase Q by adjusting the parameter values ​​related to Q.

[0049] When the user cannot reach the farthest point of the carriage by operating the excavator, the user should follow the steps below:

[0050] Step S1, the user operates the loading range matching button on the control panel;

[0051] Step S2, the control panel prompts the user to input the carriage length L, the carriage height H2 and the platform height, where the platform height is the distance between the dump truck horizontal plane and the excavator working plane;

[0052] Step S3, after the input is completed, continue to prompt the user to operate the excavator (about 10 minutes), continue to use the excavator to determine the operating rotation angle of the excavator to determine the distance between the excavator and the dump truck, and transmit the distance to the main controller;

[0053] Step S4, if the rotation operation is greater than or equal to 180 degrees, the main controller determines the size of the distance N1 and N between the counterweight and the carriage, and takes the minimum value to calculate Q; if Q ≥ L, the user is prompted to shorten the distance between the dump truck and the excavator by N1-N, and the program stops; if Q < L, the calculation makes N = N2, and the size of Q and L is re-compared: if the re-comparison result is Q ≥ L, the user is prompted to change to loading less than 180 degrees, if the re-comparison result is Q < L, the value of L is reduced until Q ≥ L, and the user is prompted to use a suitable carriage length value, if the user selects yes, the program stops, if the user selects no, the user is prompted to contact the service personnel, and the program stops;

[0054] Step S5, if the rotation operation is less than 180 degrees, as in step S4, different N values ​​are sequentially substituted to calculate the size of Q and L until Q ≥ L, and the user is recommended a suitable N value; if the N value is not suitable, different L values ​​are sequentially substituted until Q ≥ L, otherwise the user is prompted to contact the service personnel for resolution;

[0055] Among them, Q is the maximum loading length; N is the reserved safety distance between the excavator and the carriage; L is the length of the carriage; N1 is the distance between the counterweight and the carriage; N2 is the distance between the front end of the crawler and the carriage.

[0056] In a specific implementation of this embodiment, as Figure 2 As shown in the figure, the calculation formula for the farthest loading length Q is:

[0057] ;

[0058] Among them, point A is the hinge point of the boom root, point B is the hinge point of the boom upper ear plate, point C is the hinge point of the boom cylinder on the boom, point D is the overlapping hinge point of the boom and the boom, point E is the overlapping hinge point of the boom and the bucket, and the line between the hinge points is the distance between the hinge points; point F is the intersection of the horizontal line AF and the vertical line EF, r is the tooth tip circle radius of the bucket, G is the horizontal distance from the boom root hinge point to the rotation center, R is the rotation radius of the whole machine, N is the reserved safety distance between the excavator and the carriage, L is the length of the carriage, H1 is the distance from the boom root hinge point to the ground, and H2 is the height of the carriage.

[0059] like Figure 2 As shown, the calculation principle is as follows:

[0060] 1. Determine the values ​​of each parameter, It can be obtained through the initial design value, BC is the shortest distance of the boom cylinder;

[0061] 2. In △BCD, △BDA, and △CDE, the values ​​of ∠BCD, ∠BDA, and ∠CDE can be determined by the law of cosines, and then the value of ∠ADE can be determined: ∠ADE = 360° - ∠BCD - ∠BDA - ∠CDE;

[0062] 3. In △ADE, the value of AE can be determined by the law of cosines;

[0063] 4. Set the loading state to flat loading (if not flat loading, the material repose angle can be determined according to the material type to estimate the height of the material exceeding the top of the carriage), then the bucket tooth tip circle is tangent to the top of the carriage, and the length of EF can be determined: EF=H2+r-H1;

[0064] 5. In △AFE, the value of AF can be determined by the Pythagorean theorem;

[0065] 6. Determine the longest loading length Q: Q=AF+G+rRN.

[0066] Example 2

[0067] This embodiment provides an excavator, including the above-mentioned loading range and dump truck matching system.

[0068] It should be noted that, in this application, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that the process, method, article or equipment including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or equipment. In the absence of further restrictions, the elements defined by the sentence "comprise a ..." do not exclude the existence of other identical elements in the process, method, article or equipment including the elements.

[0069] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A system for matching a loading range with a dump truck, characterized in that: It includes a control panel, a main controller, an angle sensor, a first distance sensor and a second distance sensor; The control panel is used to display the information of the main controller and transmit the user instructions to the main controller for processing; The main controller is used to process user instructions, signals from the angle sensor, signals from the first distance sensor, and signals from the second distance sensor; The angle sensor is used to measure the rotation angle and transmit the rotation angle data to the main controller; The first distance sensor is used to measure the distance between the counterweight and the carriage, record it as N1, and transmit the value N1 to the main controller; The second distance sensor is used to measure the distance between the front end of the crawler track and the carriage, which is recorded as N2, and the value N2 is transmitted to the main controller.

2. A loading range and dump truck matching system according to claim 1, characterized in that: When the angle sensor detects that the rotation angle is greater than 180 degrees, the first distance sensor is activated and transmits the distance N1 between the counterweight and the car body to the main controller; when the angle sensor detects that the rotation angle is less than 180 degrees, the second distance sensor is activated and transmits the distance N2 between the front end of the belt and the car body to the main controller.

3. A loading range and dump truck matching system according to claim 1 or 2, characterized in that: It also includes a memory, which is used to receive and store data transmitted by the angle sensor, the first distance sensor and the second distance sensor; the angle sensor transmits the rotation angle data to the memory for storage; the distance N1 between the counterweight and the car body of the first distance sensor is transmitted to the memory for storage; the distance N2 between the front end of the track of the second distance sensor and the car body is transmitted to the memory for storage.

4. A method for matching a loading range with a dump truck, characterized in that: Determine the maximum loading length Q and the carriage length L; if Q ≥ L, the loading range matches this type of dump truck; if Q < L, the loading range does not match this type of dump truck, and a solution needs to be found.

5. A method for matching a loading range with a dump truck according to claim 4, characterized in that: The solution includes any of the following: Method 1: Cancel the reduction of N value and increase Q according to the actual loading angle; Method 2: Match a smaller dump truck to reduce L; Method 2: Increase Q by adjusting the parameter values ​​related to Q; the parameters related to Q include the distance AF from point A to point F, the horizontal distance G from the hinge point at the root of the boom to the center of rotation, the tooth tip circle radius r of the bucket, the rotation radius R of the whole machine, and the reserved safety distance N between the excavator and the carriage; point A is the hinge point at the root of the boom, and point F is the intersection of the horizontal line AF and the vertical line EF.

6. A method for matching a loading range with a dump truck according to claim 4, characterized in that: When the user cannot reach the farthest point of the carriage by operating the excavator, the user can follow the steps below: Step S1, the user operates the loading range matching button on the control panel; Step S2, the control panel prompts the user to input the carriage length L, the carriage height H2 and the platform height, where the platform height is the distance between the dump truck horizontal plane and the excavator working plane; Step S3, after the input is completed, continue to prompt the user to operate the excavator to determine the distance between the excavator and the dump truck, and transmit the distance to the main controller; Step S4, if the rotation operation is greater than or equal to 180 degrees, the main controller determines the size of the distance N1 and N between the counterweight and the carriage, and takes the minimum value to calculate Q; if Q ≥ L, the user is prompted to shorten the distance between the dump truck and the excavator by N1-N, and the program stops; if Q < L, the calculation makes N = N2, and the size of Q and L is re-compared: if the re-comparison result is Q ≥ L, the user is prompted to change to loading less than 180 degrees, if the re-comparison result is Q < L, the value of L is reduced until Q ≥ L, and the user is prompted to use a suitable carriage length value, if the user selects yes, the program stops, if the user selects no, the user is prompted to contact the service personnel, and the program stops; Step S5, if the rotation operation is less than 180 degrees, as in step S4, different N values ​​are sequentially substituted to calculate the size of Q and L until Q ≥ L, and the user is recommended a suitable N value; if the N value is not suitable, different L values ​​are sequentially substituted until Q ≥ L, otherwise the user is prompted to contact the service personnel for resolution; Among them, Q is the maximum loading length; N is the reserved safety distance between the excavator and the carriage; L is the length of the carriage; N1 is the distance between the counterweight and the carriage; N2 is the distance between the front end of the crawler and the carriage.

7. A method for matching a loading range with a dump truck according to claim 1 or 6, characterized in that: The calculation formula of the longest loading length Q is: ； Among them, point A is the hinge point of the boom root, point B is the hinge point of the boom upper ear plate, point C is the hinge point of the boom cylinder on the boom, point D is the overlapping hinge point of the boom and the boom, point E is the overlapping hinge point of the boom and the bucket, and the line between the hinge points is the distance between the hinge points; point F is the intersection of the horizontal line AF and the vertical line EF, r is the tooth tip circle radius of the bucket, G is the horizontal distance from the boom root hinge point to the rotation center, R is the rotation radius of the whole machine, N is the reserved safety distance between the excavator and the carriage, L is the length of the carriage, H1 is the distance from the boom root hinge point to the ground, and H2 is the height of the carriage.

8. An excavator, characterized in that: It includes the loading range and dump truck matching system as described in any one of claims 1 to 3.

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