A system and method for matching loading range with dump trucks

Abstract

This invention relates to the field of engineering machinery technology, and discloses a system and method for matching loading range with dump trucks. The system includes a control panel, a main controller, an angle sensor, a first distance sensor, and a second distance sensor. The control panel displays information from the main controller and transmits user commands to the main controller for processing. The main controller processes user commands, signals from the angle sensor, the first distance sensor, and the second distance sensor. The angle sensor measures the slewing angle and transmits the slewing angle data to the main controller. The first distance sensor measures the distance between the counterweight and the truck bed, recording it as N1, and transmits the value N1 to the main controller. The second distance sensor measures the distance between the front end of the track and the truck bed, recording it as N2, and transmits the value N2 to the main controller. This invention can accurately calculate whether the excavator's furthest loading range can reach the front end of the dump truck bed.

Description

Technical Field

[0001] This invention relates to the field of engineering machinery technology, and to a system and method for matching loading range with dump trucks, specifically to a system and method for matching excavator loading range with dump trucks. Background Technology

[0002] The suitability of the loading range of a large excavator to that of a dump truck significantly impacts loading efficiency. For example, customers aiming for maximum dump truck load capacity may require the excavator to reach the very front of the truck bed or even the very front of the cab roof during unloading. If this requirement cannot be met, the excavator operator must adjust the machine's movements, or the dump truck driver must move the vehicle, wasting time and reducing loading efficiency. Therefore, achieving a precise match between the loading range of a large excavator and the dump truck is a crucial technological challenge.

[0003] Most existing technical solutions use a combination of lidar and multiple sensors to obtain information such as the position of the vehicle compartment, thereby matching the vehicle with the system. This combination of multiple electronic devices is costly, unreliable, and its accuracy is greatly affected by the environment and operating conditions. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a system and method for matching loading range with dump trucks, which can accurately calculate whether the excavator's furthest loading range can reach the front end of the dump truck's cargo box.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] In a first aspect, the present invention proposes a loading range matching system for dump trucks, 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 information from the main controller and transmit user commands to the main controller for processing.

[0008] The main controller is used to process user commands, 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 track and the carriage, which is recorded as N2, and the value N2 is transmitted to the main controller.

[0012] In conjunction with the first aspect, the first distance sensor is further disposed at the rear end of the counterweight, and the second distance sensor is disposed on the rotary platform.

[0013] In conjunction with the first aspect, further, when the angle sensor detects a rotation angle 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 a rotation angle 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 conjunction with the first aspect, the loading range matching system for dump trucks of the present invention further includes a memory, which is used to receive and store data transmitted from 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 of the first distance sensor and the truck bed is transmitted to the memory for storage; and the distance N2 between the front end of the track of the second distance sensor and the truck bed is transmitted to the memory for storage.

[0015] Secondly, this invention proposes a method for matching the loading range with a dump truck, including:

[0016] Determine the relationship between the furthest loading length Q and the truck body 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 sought.

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

[0018] Method 1: Based on the actual loading angle, cancel the reduction of N and increase Q;

[0019] Method 2: Match with a smaller dump truck, reducing the length (L);

[0020] 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 boom root hinge point to the center of rotation, the radius r of the bucket tooth tip, the overall rotation radius R, and the reserved safety distance N between the excavator and the truck bed.

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

[0022] In conjunction with the second point, furthermore, when the user cannot reach the furthest point of the excavator from the truck bed, the user should follow these steps:

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

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

[0025] Step S3: After the input is completed, the user will be prompted to operate the excavator (for about 10 minutes). The excavator will continue to determine the working slewing angle to determine the distance between the excavator and the dump truck, and transmit this distance to the main controller.

[0026] Step S4: If the operation involves a 180-degree or greater turn, the main controller determines the distances N1 and N between the counterweight and the truck bed, and calculates Q using the minimum value. 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 system calculates to make N = N2 and re-compares Q and L. If the re-compare result is Q ≥ L, the user is prompted to change the loading angle to less than 180 degrees. If the re-compare result is Q < L, the value of L is reduced until Q ≥ L. The user is then prompted to use an appropriate truck bed length. If the user selects "Yes," the program stops. If the user selects "No," the user is prompted to contact service personnel, and the program stops.

[0027] Step S5: If the rotation is less than 180 degrees, proceed as in step S4, successively substituting different N values ​​to calculate the values ​​of Q and L until Q ≥ L, and recommend a suitable N value to the user; if the N value is not suitable, successively substituting different L values ​​until Q ≥ L, otherwise prompt the user to contact service personnel for assistance.

[0028] Where Q is the furthest loading length; N is the reserved safe distance between the excavator and the truck bed; L is the length of the truck bed; N1 is the distance between the counterweight and the truck bed; and N2 is the distance between the front end of the track and the truck bed.

[0029] In conjunction with the second aspect, the formula for calculating the furthest loading length Q is as follows:

[0030] ;

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

[0032] Thirdly, the present invention proposes an excavator including the aforementioned loading range and dump truck matching system.

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

[0034] (1) This invention uses a combination of quantitative and variable methods of the key dimensions of the excavator to accurately determine the farthest loading range. Based on the calculation results of the farthest loading range, the parameters that need to be changed for matching the machine and the vehicle can be accurately identified. Through theoretical calculation, it can be determined whether the farthest loading range of the excavator can reach the front end of the dump truck body, which has high accuracy.

[0035] (2) When designing the working device in the initial stage, the present invention can facilitate the designer to verify the rationality of the structural size design, realize the matching of excavator and dump truck, and improve work efficiency.

[0036] (3) When the scope of market feedback exploration is insufficient, the present invention does not require redrawing 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, which is highly flexible. Attached Figure Description

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

[0039] Figure 2 This is a schematic diagram illustrating the calculation principle of the matching method in Example 1. Detailed Implementation

[0040] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0041] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps set forth in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may include different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0042] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "upper", "lower", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only used to facilitate the description of the present invention and to simplify the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting the scope of protection of the present invention.

[0043] Example 1

[0044] like Figure 1 As shown, the loading range matching system for dump trucks in 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 information from the main controller and transmit user commands to the main controller for processing. The main controller is used to process user commands, 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 slewing angle and transmit the slewing angle data to the main controller. The first distance sensor is located at the rear end of the counterweight and is used to measure the distance between the counterweight and the truck bed, recorded as N1, and transmit the value N1 to the main controller. The second distance sensor is located on the slewing platform and is used to measure the distance between the front end of the track and the truck bed, recorded as N2, and transmit the value N2 to the main controller.

[0045] In one specific implementation of this embodiment, the loading range and dump truck matching system of this embodiment further includes a memory. The memory is used to receive and store data transmitted from 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 truck bed of the first distance sensor is transmitted to the memory for storage. The distance N2 between the front end of the track and the truck bed of the second distance sensor is transmitted to the memory for storage.

[0046] When the angle sensor detects a rotation angle 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 and the memory; when the angle sensor detects a rotation angle 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 and the memory.

[0047] The method for matching the loading range with the dump truck in this embodiment includes: determining the size of the furthest loading length Q and the length L of the truck body; 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 sought.

[0048] In one specific implementation of this embodiment, if the loading range does not match the type of dump truck, the problem can be solved in three ways: First, reduce the value of N 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 excavator from the truck bed, the user should follow these steps:

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

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

[0052] Step S3: After the input is completed, the user will be prompted to operate the excavator (for about 10 minutes). The excavator will continue to determine the working slewing angle to determine the distance between the excavator and the dump truck, and transmit this distance to the main controller.

[0053] Step S4: If the operation involves a 180-degree or greater turn, the main controller determines the distances N1 and N between the counterweight and the truck bed, and calculates Q using the minimum value. 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 system calculates to make N = N2 and re-compares Q and L. If the re-compare result is Q ≥ L, the user is prompted to change the loading angle to less than 180 degrees. If the re-compare result is Q < L, the value of L is reduced until Q ≥ L. The user is then prompted to use an appropriate truck bed length. If the user selects "Yes," the program stops. If the user selects "No," the user is prompted to contact service personnel, and the program stops.

[0054] Step S5: If the rotation is less than 180 degrees, proceed as in step S4, successively substituting different N values ​​to calculate the values ​​of Q and L until Q ≥ L, and recommend a suitable N value to the user; if the N value is not suitable, successively substituting different L values ​​until Q ≥ L, otherwise prompt the user to contact service personnel for assistance.

[0055] Where Q is the furthest loading length; N is the reserved safe distance between the excavator and the truck bed; L is the length of the truck bed; N1 is the distance between the counterweight and the truck bed; and N2 is the distance between the front end of the track and the truck bed.

[0056] One specific implementation method in this embodiment is as follows: Figure 2 As shown, the formula for calculating the furthest loading length Q is:

[0057] ;

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

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

[0060] 1. Determine the values ​​of each parameter. It can be obtained from the initial design values, where 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 using the Law of Cosines, and thus the value of ∠ADE can be determined: ∠ADE = 360° - ∠BCD - ∠BDA - ∠CDE;

[0062] 3. The value of AE can be determined in △ADE using the Law of Cosines;

[0063] 4. Set the loading status 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 above the top of the car body), then the tip circle of the bucket tooth is tangent to the top of the car body, and the length of EF can be determined: EF=H2+r-H1;

[0064] 5. The value of AF in △AFE can be determined using the Pythagorean theorem;

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

[0066] Example 2

[0067] This embodiment proposes 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" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

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

Claims

1. A method for matching loading range with dump trucks, characterized in that: Determine the relationship between the furthest loading length Q and the truck body 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 sought. The solution includes any of the following methods: Method 1: Based on the actual loading angle, cancel the reduction of N and increase Q; Method 2: Match with a smaller dump truck, reducing the length (L); Method 2: Increase Q by adjusting the parameters related to Q; the parameters related to Q include the distance AF from point A to point F, the horizontal distance G from the boom root hinge point to the center of rotation, the radius r of the bucket tooth tip, the overall machine rotation radius R, and the reserved safety distance N between the excavator and the truck bed; where point A is the boom root hinge point, and point F is the intersection of the horizontal line AF and the vertical line EF; When the user cannot reach the farthest point of the excavator from the truck bed, the user should follow these steps: Step S1: The user operates the vehicle loading range matching button on the control panel; In step S2, the control panel prompts the user to input the length L of the dump truck, the height H2 of the dump truck, and the height of the platform, where the height of the platform is the distance between the horizontal plane of the dump truck and the working plane of the excavator. Step S3: After the input is completed, the user is prompted to operate the excavator to determine the distance between the excavator and the dump truck, and the distance is transmitted to the main controller. Step S4: If the operation involves a 180-degree or greater turn, the main controller determines the distances N1 and N between the counterweight and the truck bed, and calculates Q using the minimum value. 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 system calculates to make N = N2 and re-compares Q and L. If the re-compare result is Q ≥ L, the user is prompted to change the loading angle to less than 180 degrees. If the re-compare result is Q < L, the value of L is reduced until Q ≥ L. The user is then prompted to use an appropriate truck bed length. If the user selects "Yes," the program stops. If the user selects "No," the user is prompted to contact service personnel, and the program stops. Step S5: If the rotation is less than 180 degrees, proceed as in step S4, successively substituting different N values ​​to calculate the values ​​of Q and L until Q ≥ L, and recommend a suitable N value to the user; if the N value is not suitable, successively substituting different L values ​​until Q ≥ L, otherwise prompt the user to contact service personnel for assistance. Where Q is the furthest loading length; N is the reserved safe distance between the excavator and the truck bed; L is the length of the truck bed; N1 is the distance between the counterweight and the truck bed; and N2 is the distance between the front end of the track and the truck bed.

2. The method for matching loading range with dump trucks according to claim 1, characterized in that: The formula for calculating the furthest loading length Q is: ； Wherein, point A is the boom root hinge point, point B is the boom upper ear plate hinge point, point C is the stick cylinder hinge point on the stick, point D is the coincident hinge point of the boom and stick, point E is the coincident hinge point of the stick and bucket, and the line connecting each hinge point is the distance between each hinge point; point F is the intersection of the horizontal line AF and the vertical line EF, r is the radius of the bucket tooth tip circle, G is the horizontal distance from the boom root hinge point to the center of rotation, R is the overall machine rotation radius, N is the reserved safety distance between the excavator and the truck bed, L is the length of the truck bed, H1 is the distance from the boom root hinge point to the ground, and H2 is the height of the truck bed.

3. A loading range matching system for dump trucks, characterized in that: The method for matching the loading range with the dump truck as described in claim 1 or 2 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 information from the main controller and transmit user commands to the main controller for processing. The main controller is used to process user commands, 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 track and the carriage, which is recorded as N2, and the value N2 is transmitted to the main controller.

4. The loading range matching system for dump trucks according to claim 3, characterized in that: When the angle sensor detects a rotation angle 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 a rotation angle 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.

5. A loading range matching system for dump trucks according to claim 3 or 4, characterized in that: It also includes a memory, which is used to receive and store data transmitted from 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 of the first distance sensor and the carriage is transmitted to the memory for storage; the distance N2 between the front end of the track of the second distance sensor and the carriage is transmitted to the memory for storage.

6. An excavator, characterized in that: Includes the loading range matching system for dump trucks as described in claim 3 or 4.

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