Excavator bucket tooth abrasion detection system and method

Abstract

The invention discloses an excavator bucket tooth abrasion detection system and method. The excavator bucket tooth abrasion detection system comprises a sensor system, a control system and an interaction system. The sensor system and the interaction system are in signal connection with the control system; on one hand, the control system sends a guide signal to the interaction system according to a bucket tooth wear detection enable signal, so that an operator controls an excavator bucket to complete two posture positioning in sequence according to guide information, and on the other hand, the control system processes and stores the posture information data of the excavator in real time and calculates the bucket tooth wear amount according to a bucket tooth wear calculation signal. The processed attitude information and the calculated bucket tooth abrasion loss information are sent to an interaction system together; and the control system judges whether to send an alarm signal to the interaction system according to the bucket tooth abrasion loss calculation result. According to the invention, automatic online detection of bucket tooth wear is realized, and the manual intervention demand is obviously reduced. The system reduces the hardware cost by multiplexing the existing sensor, and adapts to the continuous operation requirements under complex working conditions.

Description

Technical Field

[0001] The present invention relates to the technical field of intelligent control of engineering machinery, and in particular to a system and method for detecting bucket tooth wear of an excavator. Background Art

[0002] In the field of construction machinery, excavator bucket teeth are critical components that come into direct contact with materials, and their wear directly impacts operational efficiency and equipment performance. Traditional bucket tooth wear detection relies primarily on manual visual inspection or physical measurement, which is not only inefficient but also difficult to accurately quantify. With the development of intelligent technology, image recognition-based detection methods have begun to be used. However, these solutions are susceptible to environmental interference in complex operating conditions and require additional hardware installation, increasing system costs and maintenance difficulties. Existing technologies generally suffer from insufficient detection accuracy, poor environmental adaptability, and cumbersome operation, failing to meet the demands of modern intelligent construction machinery operations. In particular, in intelligent measurement systems for excavators, bucket tooth wear can lead to accumulated end-point positioning errors, severely impacting measurement accuracy. While some solutions attempt to utilize built-in sensor data for wear assessment, they lack effective kinematic modeling and dual-pose comparison mechanisms, making it difficult to achieve high-precision wear calculations. Furthermore, existing technologies fail to establish a complete closed-loop detection system and effectively link wear detection results with intelligent measurement systems, hindering overall operational accuracy. Summary of the Invention

[0003] In view of this, the present invention provides an excavator bucket tooth wear detection system, which has the technical effects of realizing automated detection, improving measurement accuracy, and reducing manual intervention.

[0004] To achieve the above object, the present invention provides the following technical solutions: A bucket tooth wear detection system for an excavator includes a sensor system, a control system and an interactive system.

[0005] Among them, the sensor system and the interactive system are both connected to the control system signal; the sensor system is used to obtain and transmit the excavator posture information data to the control system in real time; the interactive system is used to send bucket tooth wear detection enable signal and bucket tooth wear calculation signal to the control system, display the current excavator posture information, bucket tooth wear information and guidance information on the instrument display, and issue an alarm prompt; on the one hand, the control system sends a guidance signal to the interactive system according to the bucket tooth wear detection enable signal, so that the operator controls the excavator bucket to complete two posture positioning in sequence according to the guidance information; on the other hand, the excavator posture information data is processed and stored in real time, and the bucket tooth wear is calculated according to the bucket tooth wear calculation signal. The processed posture information and the calculated bucket tooth wear information are sent to the interactive system together; the control system determines whether to send an alarm signal to the interactive system based on the bucket tooth wear calculation result.

[0006] Preferably, the control system includes a communication module, a central processing unit and a storage module. The communication module is used for receiving and sending data. The sensor system and the interactive system are both connected to the communication module signal. The central processing unit is used for data processing and calculation. The storage module is used to store control programs, data calculation algorithms and calculation result data.

[0007] Preferably, the sensor system includes: a boom angle sensor, a dipper arm angle sensor, a bucket angle sensor and a slewing platform angle sensor. The four angle sensors are all connected to the communication module signal. The boom angle data, dipper arm angle data, bucket angle data and slewing platform angle data respectively obtained by the four angle sensors constitute the excavator posture information data.

[0008] The present invention also proposes a method for detecting bucket tooth wear of an excavator, which is applied to the excavator bucket tooth wear detection system described in the above embodiment, including: S1, angle data acquisition and processing; S2, operation-guided dual-posture positioning; S3, tooth tip theoretical position calculation; S4, tooth tip position difference calculation; S5, bucket tooth wear amount calculation; S6, over-threshold alarm.

[0009] Preferably, step S1 includes: obtaining the original angle data of the slewing platform, boom, arm, and bucket; calibrating and calculating the original angle data to obtain the joint angle data of the slewing platform, boom, arm, and bucket; processing the joint angle data with the Kalman filter algorithm; and sending the processed joint angle data to the interactive system.

[0010] Preferably, step S2 includes: controlling the excavator bucket to complete a first posture positioning according to the guidance information; and controlling the excavator bucket to complete a second posture positioning according to the guidance information.

[0011] Preferably, step S3 includes: using the DH parameter method to define the base coordinate system, the boom joint coordinate system, the arm joint coordinate system, the bucket joint coordinate system and the bucket tooth endpoint coordinate system; constructing a kinematic model from the excavator rotation center to the bucket tooth endpoint; obtaining the DH parameters and joint variables of the excavator working device: bringing the DH parameters and joint variables of the excavator working device into the transformation matrix to obtain the transformation matrix from the base coordinate system to the bucket coordinate system; and calculating the theoretical coordinates of the bucket tooth tip in the base coordinate system according to the transformation matrix.

[0012] Preferably, in the DH parameter method: the Z axis is the motion axis of the joint, the X axis is the common normal of two adjacent Z axes, and the Y axis is determined according to the right-hand rectangular coordinate system composed of XYZ; in the base coordinate system, the excavator rotation center is the origin; in the boom joint coordinate system, the hinge point of the boom and the turntable is the origin; in the arm joint coordinate system, the hinge point of the boom and the arm is the origin; in the bucket joint coordinate system, the hinge point of the arm and the bucket is the origin; in the bucket joint coordinate system, the hinge point of the arm and the bucket is the origin; in the bucket tooth endpoint coordinate system, the bucket tooth tip is the origin.

[0013] Preferably, step S4 includes: verifying whether the theoretical coordinates of the bucket tooth tip in the first posture and the second posture satisfy the formula: Where, is the actual coordinate of the bucket tooth tip, is the theoretical coordinate of the bucket tooth tip in the first posture, is the theoretical coordinate of the tooth tip of the bucket tooth in the second posture; If the theoretical coordinates of the bucket tooth tip in the first and second postures satisfy the formula, the bucket tooth tip is not worn; if the theoretical coordinates of the bucket tooth tip in the first and second postures do not satisfy the formula, the bucket tooth tip is worn. At this time, according to the position deviation vector: And the position deviation calculation formula: , calculate the theoretical position deviation of the bucket tooth tip after wear; where, is the theoretical position deviation of the bucket tooth tip after wear, is the theoretical three-axis coordinate of the bucket tooth tip in the first posture, is the theoretical three-axis coordinate of the bucket tooth tip in the second posture, It is the difference between the theoretical three-axis coordinates of the bucket tooth tip in the first posture and the theoretical three-axis coordinates of the bucket tooth tip in the second posture.

[0014] Preferably, step S5 includes: according to the formula: , calculate the bucket tooth wear, where, is the bucket tooth wear, is the theoretical position deviation of the bucket tooth tip after wear, is the angle of the bucket joint in the two postures; when hour, , the formula can be simplified to: ;when hour, , the formula can be simplified to: .

[0015] Preferably, step S6 includes: the control system compares the calculated current bucket tooth wear with a preset wear threshold; when the bucket tooth wear is greater than the preset wear threshold, the control system sends an alarm signal to the interactive system, and the interactive system displays an alarm prompt on the instrument interface to remind the operation and maintenance service personnel to replace the bucket teeth in time; when the bucket tooth wear is less than or equal to the preset wear threshold, the control system does not send an alarm signal.

[0016] The beneficial effects of this invention are as follows: Compared with existing technologies, this application achieves automated online detection of bucket tooth wear, significantly reducing the need for manual intervention. By reusing existing sensors, the system reduces hardware costs and adapts to continuous operation requirements under complex working conditions. A dual-posture positioning difference algorithm effectively eliminates mechanical system errors and improves the accuracy of wear calculations. Detection results are directly linked to intelligent measurement system parameters, forming a self-correcting closed-loop control system that ensures the long-term operational accuracy of construction machinery.

[0017] Additional aspects and advantages of the present invention will be set forth in part in the description which follows and, in part, will be obvious from the description which follows, or may be learned by practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 is a flow chart of the excavator bucket tooth wear detection method of the present invention; Figure 2 is a schematic structural diagram of the excavator (with a coordinate system) of the present invention; Figure 3 Schematic diagram of kinematic modeling of an excavator using the DH parameter method of the present invention; Figure 4 is the angle between the two-position bucket joints of the present invention Schematic diagram of bucket posture when =180°; Figure 5 is the angle between the two-position bucket joints of the present invention Schematic diagram of bucket posture when =90°. DETAILED DESCRIPTION

[0019] The following describes embodiments of the present invention in detail, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and are not to be construed as limiting the present invention.

[0020] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature identified as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, "plurality" means two or more, unless otherwise specifically defined.

[0021] Reference below Figures 1 to 5 The present invention will be described in detail with respect to an excavator bucket tooth wear detection system according to an embodiment of the present invention.

[0022] An embodiment of the present application discloses an excavator bucket tooth wear detection system, including: a sensor system, a control system and an interactive system.

[0023] Among them, the sensor system and the interactive system are both connected to the control system signal; the sensor system is used to obtain and transmit the excavator posture information data to the control system in real time; the interactive system is used to send bucket tooth wear detection enable signal and bucket tooth wear calculation signal to the control system, display the current excavator posture information, bucket tooth wear information and guidance information on the instrument display, and issue an alarm prompt; on the one hand, the control system sends a guidance signal to the interactive system according to the bucket tooth wear detection enable signal, so that the operator controls the excavator bucket to complete two posture positioning in sequence according to the guidance information; on the other hand, the excavator posture information data is processed and stored in real time, and the bucket tooth wear is calculated according to the bucket tooth wear calculation signal. The processed posture information and the calculated bucket tooth wear information are sent to the interactive system together; the control system determines whether to send an alarm signal to the interactive system based on the bucket tooth wear calculation result.

[0024] Specifically, once the operator initiates the inspection process, the interactive system displays posture adjustment instructions, guiding the bucket to two different angles. The sensor system collects real-time joint angle data, which is filtered and processed by the control system before being input into the kinematic model. The model constructs a coordinate transformation matrix based on the DH parameter method and calculates the theoretical tooth tip coordinates for each of the two postures. The control system compares the vector difference between the two theoretical coordinates and, based on geometric trigonometric relationships, derives the actual wear amount. If the measured value exceeds a preset threshold, the interactive system triggers an audible and visual alarm, completing the closed-loop inspection process from data acquisition to decision-making.

[0025] Compared to existing technologies, traditional manual inspections require machine downtime and component disassembly for measurement. This solution reuses existing sensors for online inspection, avoiding operational interruptions. Compared to image recognition solutions that rely on external cameras, this method directly utilizes mechanical kinematic parameters, eliminating the influence of environmental interference. Existing intelligent measurement systems fail to account for the accumulated errors caused by bucket tooth wear. This solution utilizes a closed-loop parameter correction mechanism to ensure the long-term accuracy and stability of the measurement system.

[0026] Through the above-mentioned technical solution, this application achieves automated online detection of bucket tooth wear, significantly reducing the need for manual intervention. By reusing existing sensors, the system reduces hardware costs and adapts to continuous operation requirements under complex working conditions. A dual-posture positioning difference algorithm effectively eliminates mechanical system errors and improves the accuracy of wear calculations. Detection results are directly linked to intelligent measurement system parameters, forming a self-correcting closed-loop control system that ensures the long-term operational accuracy of construction machinery.

[0027] In some embodiments, the control system includes a communication module, a central processing unit and a storage module. The communication module is used to receive and send data. The sensor system and the interactive system are both connected to the communication module signal. The central processing unit is used for data processing and calculation. The storage module is used to store control programs, data calculation algorithms and calculation result data.

[0028] Specifically, the communication module establishes a signal connection with the sensor system and receives raw angle data for each joint in a standardized data frame format. The central processing unit performs coordinate transformation calculations on this raw angle data, converting the angle values ​​in the direction of gravity acceleration into the joint rotation angles required by the DH parameter model. This calculation eliminates sensor noise interference using a Kalman filter algorithm. The storage module is pre-installed with a kinematic modeling package containing homogeneous transformation matrix generation functions and coordinate calculation algorithms. During dual-pose positioning, the corresponding program segments are automatically retrieved to perform theoretical tooth tip coordinate calculations. The resulting data is stored in a database, providing a foundation for subsequent wear trend analysis.

[0029] Compared with existing technologies, traditional bucket tooth inspection solutions require the installation of additional laser rangefinders or visual sensors, which are associated with high hardware costs and complex installation. This solution reuses the excavator's existing angle sensors to build a data acquisition system and uses the control system's built-in algorithm to calculate wear, avoiding the wiring modifications and compatibility issues associated with external inspection equipment.

[0030] Through the above technical solution, this application effectively solves the hardware dependency of traditional detection methods, achieving zero hardware modification cost for excavator bucket tooth wear detection. The multi-protocol compatibility of the communication module enables the system to adapt to different brands and models of sensor devices. The embedded architecture of the central processing unit ensures real-time calculations even in environments with limited computing power. The historical data archiving function of the storage module provides training samples for the wear prediction model, forming a complete technical closed loop from data acquisition to decision output.

[0031] In some embodiments, the sensor system includes: a boom angle sensor, a dipper arm angle sensor, a bucket angle sensor and a slewing platform angle sensor. The four angle sensors are all connected to the communication module signal. The boom angle data, dipper arm angle data, bucket angle data and slewing platform angle data respectively obtained by the four angle sensors constitute the excavator posture information data.

[0032] The boom angle sensor measures the rotation angle of the boom and turntable hinge. By detecting changes in the boom's rotation angle around the hinge axis, it reflects the boom's lifting or lowering status in the vertical plane in real time. The arm angle sensor measures the arm's rotation angle relative to the boom hinge. By detecting the arm's swing angle around the hinge axis, it reflects the arm's extension and retraction status in the horizontal plane. The bucket angle sensor measures the bucket's rotation angle relative to the arm hinge. By detecting the bucket's rotation angle around the hinge axis, it reflects the bucket's opening and closing status. The slewing platform angle sensor measures the excavator's center of rotation offset relative to its initial azimuth. By detecting changes in the angular motion of the entire machine, it reflects the excavator's overall steering status in the horizontal plane.

[0033] Specifically, four angle sensors independently measure the different motion joints of the excavator's working device, forming a complete posture data acquisition network. The boom angle sensor captures the boom's vertical lift angle, the arm angle sensor records the arm's horizontal extension angle, the bucket angle sensor monitors the bucket's opening and closing angles, and the slewing platform angle sensor captures the overall machine's rotational azimuth. These four types of sensors synchronize data transmission via a communication module, integrating previously dispersed joint motion parameters into unified posture information data. When the excavator performs dual-posture positioning operations, the boom angle sensor and arm angle sensor jointly determine the spatial extension state of the working device, the bucket angle sensor provides the bucket's end-point posture parameters, and the slewing platform angle sensor eliminates the influence of the machine's steering on end-point positioning. After coordinate conversion of the four-dimensional angle data, the theoretical coordinates of the bucket tooth end in the base coordinate system can be accurately calculated, providing complete raw data support for subsequent dual-posture difference calculations.

[0034] Through the above technical solution, this application solves the problem of incomplete collection of excavator posture information. Through the coordinated work of four key angle sensors, it fully covers the motion parameters of each joint of the working device and provides multi-dimensional data input for bucket tooth wear calculation. At the same time, this solution directly utilizes the original sensor resources of the excavator, avoiding reliance on manual measurement or external detection equipment. While ensuring real-time data collection, it significantly reduces the cost of system modification and improves the operational convenience of the detection process. The fusion application of four types of sensor data effectively supports the operation of the dual-posture positioning difference calculation model, ensuring the accuracy of the bucket tooth wear calculation results.

[0035] The present invention also proposes a method for detecting bucket tooth wear of an excavator, which is applied to the bucket tooth wear detection system of the excavator in the above embodiment, including: S1, angle data acquisition and processing; S2, operation-guided dual-posture positioning; S3, calculation of theoretical position of tooth tip; S4, calculation of tooth tip position difference; S5, calculation of bucket tooth wear amount; S6, over-threshold alarm.

[0036] Among them, angle data acquisition and processing is to obtain raw angle data through sensors of the rotary platform, boom, dipper arm, and bucket, and obtain joint angle data after calibration, calibration, and filtering, providing high-precision input for subsequent calculations. Operation-guided dual-posture positioning is to guide the operator to control the bucket through an interactive system to position the bucket tooth tip to the same physical point in two different postures, thereby establishing the constraints required for detection. The theoretical position calculation of the tooth tip is to use the DH parameter method to construct a kinematic model, convert the joint angle into the theoretical coordinates of the bucket tooth end in the base coordinate system, and realize the mathematical abstraction of the mechanical structure. The calculation of the tooth tip position difference is to reversely infer the positioning deviation caused by bucket tooth wear by the difference in theoretical coordinates under two postures. The calculation of bucket tooth wear is to establish a mathematical model of deviation and wear based on geometric relationships, and convert the spatial coordinate difference into actual wear length. The over-threshold alarm is to compare the calculation result with the preset threshold, triggering an alarm signal to indicate maintenance needs.

[0037] Specifically, this method first collects and processes multi-joint angle data to ensure input data reliability. It then guides the operator through dual-position positioning, using a kinematic model to calculate the theoretical bucket tooth coordinates for each position. By comparing the difference between the two theoretical coordinates and combining them with the bucket joint angle parameters, the actual tooth wear is deduced. Finally, the wear is compared with a preset threshold, triggering an alarm mechanism. This entire process reuses data from the excavator's built-in sensors, eliminating the need for manual intervention or additional equipment, creating a closed-loop detection process.

[0038] Compared with existing technologies, traditional manual visual inspection requires downtime and is inefficient; physical measurement relies on contact tools and is susceptible to interference from working conditions; and image recognition requires additional hardware and has poor environmental adaptability. This method reuses existing sensor data and combines dual-posture positioning difference analysis to achieve non-contact automated inspection, eliminating downtime, reducing hardware costs, and improving inspection stability under complex working conditions.

[0039] Through the above technical solution, this application solves the problems of traditional detection methods, such as low efficiency and reliance on manual operation and external equipment, and achieves non-contact, high-precision detection of bucket tooth wear. This method integrates dual-posture positioning differences with a kinematic model to eliminate the impact of environmental interference on detection accuracy. It also uses built-in sensor data to build a closed-loop calculation process, significantly improving the degree of detection automation and providing reliable support for intelligent excavator operation and maintenance.

[0040] In this embodiment, step S1 includes: obtaining the original angle data of the slewing platform, boom, arm, and bucket; calibrating and calculating the original angle data to obtain the joint angle data of the slewing platform, boom, arm, and bucket; processing the joint angle data using the Kalman filter algorithm; and sending the processed joint angle data to the interactive system.

[0041] Calibration and calibration calculations modify raw angle data using a preset sensor error compensation model to eliminate the systematic effects of sensor zero drift and mechanical installation errors on angle measurement. Kalman filtering algorithms dynamically suppress noise in joint angle data using a state-space model, reducing random noise interference and improving data stability.

[0042] Specifically, the original angle data is first obtained from each joint angle sensor, and the sensor zero point offset and mechanical installation error are eliminated through calibration, and the original angle is converted into joint angle parameters that conform to the kinematic model definition; then the Kalman filter algorithm is used to process the joint angle data in real time, and the dynamic noise interference is suppressed through the prediction-correction mechanism to generate high-precision joint angle data; finally, the processed angle data is transmitted to the interactive system in real time to provide reliable input for operation guidance and subsequent wear calculation.

[0043] Through the above technical solution, this application effectively solves the problems of noise interference, zero point drift and installation error in the original data of the excavator angle sensor, significantly improves the measurement accuracy of the joint angle data, and provides a reliable data basis for the subsequent dual-posture difference calculation of bucket tooth wear, thereby ensuring the accuracy of the overall detection system.

[0044] In this embodiment, step S2 includes: controlling the excavator bucket to achieve a first posture positioning according to the guidance information; and controlling the excavator bucket to achieve a second posture positioning according to the guidance information. Step S3 includes: defining the base coordinate system, the boom joint coordinate system, the arm joint coordinate system, the bucket joint coordinate system, and the bucket tooth endpoint coordinate system using the DH parameter method; constructing a kinematic model from the excavator's rotation center to the bucket tooth endpoint; obtaining the DH parameters and joint variables of the excavator's working device; substituting the DH parameters and joint variables of the excavator's working device into the transformation matrix to obtain a transformation matrix from the base coordinate system to the bucket coordinate system; and calculating the theoretical coordinates of the bucket tooth tip in the base coordinate system based on the transformation matrix. In the DH parameter method: the Z axis is the motion axis of the joint, the X axis is the common normal of the two adjacent Z axes, and the Y axis is determined by the right-hand rectangular coordinate system composed of XYZ; in the base coordinate system, the excavator's rotation center is the origin; in the boom joint coordinate system, the hinge point between the boom and the turntable is the origin; in the arm joint coordinate system, the hinge point between the boom and the arm is the origin; in the bucket joint coordinate system, the hinge point between the arm and the bucket is the origin; in the bucket tooth endpoint coordinate system, the bucket tooth tip is the origin.

[0045] The DH parameter method is a modeling approach that describes the kinematic relationships of multi-joint mechanical systems using a homogeneous transformation matrix. Specifically, four parameters (rod length, torsion angle, joint angle, and horizontal distance) are used to define the transformation relationship between adjacent joint coordinate systems, thereby constructing a kinematic chain from the base to the end effector. The base coordinate system is a global coordinate system based on the excavator's rotation center. The origin position is determined by the slewing platform angle sensor data and is used to unify spatial coordinate calculations under different postures. Joint variables are the angle parameters of joints such as the boom, arm, and bucket. They are collected from corresponding angle sensors and obtained through filtering and calibration, serving as input parameters for the kinematic model. The transformation matrix is ​​a homogeneous transformation matrix generated based on the DH parameters and joint variables. Matrix multiplication is used to obtain the coordinate transformation relationship from the base coordinate system to the bucket tooth endpoint, enabling theoretical calculation of the end position.

[0046] Specifically, the center of rotation is defined as the origin in the base coordinate system, and the local coordinate systems of the boom, arm, and bucket are established in sequence using the DH parameter method. The Z axis of each joint coordinate system is along the joint rotation axis, the X axis is along the common normal of the adjacent Z axis, and the Y axis is determined according to the right-hand rule. By collecting the angle data of each joint and substituting it into the DH parameters, the homogeneous transformation matrix between adjacent coordinate systems is calculated step by step. By multiplying each transformation matrix, the total transformation matrix from the base coordinate system to the bucket tooth endpoint is obtained. From this, the position component is extracted to obtain the theoretical coordinates of the bucket tooth tip in the base coordinate system. For example, the origin of the boom joint coordinate system is located at the hinge point between the boom and the turntable, its Z axis is perpendicular to the hinge surface, and its X axis points in the direction of boom extension. When the boom angle changes, the bucket tooth position coordinates are updated using the corresponding rotation transformation matrix. This calculation process eliminates the influence of posture changes such as fuselage rotation and boom pitch on coordinate positioning, ensuring that the theoretical coordinates under different postures are unified to the same reference system.

[0047] Through the above technical solution, this application can accurately eliminate bucket tooth positioning errors caused by changes in the machine body's posture. Using a kinematic model, the multi-joint angle data is converted into theoretical coordinates in a base coordinate system, providing a unified benchmark for dual-posture difference calculations. This solution achieves high-precision theoretical calculations of the bucket tooth's end position, ensuring that wear measurement results are unaffected by the complex motion of the mechanical structure, and resolving the technical drawback of traditional methods that often lead to positioning deviations due to posture differences.

[0048] In this embodiment, step S4 includes: verifying whether the theoretical coordinates of the bucket tooth tip in the first posture and the second posture satisfy the formula: Where, is the actual coordinate of the bucket tooth tip, is the theoretical coordinate of the bucket tooth tip in the first posture, is the theoretical coordinate of the tooth tip in the second posture; if the theoretical coordinates of the tooth tip in the first posture and the second posture satisfy the formula, the tooth tip is not worn; if the theoretical coordinates of the tooth tip in the first posture and the second posture do not satisfy the formula, the tooth tip is worn. At this time, according to the position deviation vector: And the position deviation calculation formula: , calculate the theoretical position deviation of the bucket tooth tip after wear; where, is the theoretical position deviation of the bucket tooth tip after wear, is the theoretical three-axis coordinate of the bucket tooth tip in the first posture, is the theoretical three-axis coordinate of the bucket tooth tip in the second posture, It is the difference between the theoretical three-axis coordinates of the bucket tooth tip in the first posture and the theoretical three-axis coordinates of the bucket tooth tip in the second posture.

[0049] Specifically, during the two posture positioning processes, if the Euclidean distance between the theoretical coordinates and the actual reference point coordinates is zero, it is determined that the bucket teeth are not worn; if there is a deviation, the spatial deviation is calculated by the vector difference between the two theoretical coordinates. This process avoids the complexity of directly measuring reference points by comparing the theoretical coordinate calculations of the kinematic model with actual physical positioning. It also uses the coordinate differences between the two independent postures to eliminate sensor noise and positioning errors, transforming wear calculation into a geometric spatial relationship problem. Through vector operations and scalar conversion, a mathematical model is established to link the three-dimensional spatial deviation with the change in bucket tooth length, providing standardized input parameters for subsequent wear calculations.

[0050] Through the above technical solution, this application realizes non-contact high-precision bucket tooth wear detection, solves the problems of low efficiency and poor accuracy of traditional methods, and effectively reduces the need for manual intervention through difference analysis between theoretical models and measured data, while avoiding interference of complex working conditions on the detection process.

[0051] In this embodiment, step S5 includes: according to the formula: , calculate the bucket tooth wear, where, is the bucket tooth wear, is the theoretical position deviation of the bucket tooth tip after wear, is the angle of the bucket joint in the two postures; when hour, , the formula can be simplified to: ;when hour, , the formula can be simplified to: .

[0052] Specifically, this method associates the theoretical position deviation with the bucket joint angle by establishing a geometric kinematic model. When the operator controls the bucket to complete two different posture positioning, the system automatically collects the joint angle data under the two postures and calculates the theoretical coordinates of the bucket tooth tip respectively through the kinematic model. Since the actual bucket tooth tip is forced to contact the same physical point, the length change caused by wear will cause deviations in the two theoretical coordinates. By introducing the trigonometric function relationship, the position deviation is associated with the bucket joint angle. Angle with bucket joint Perform mathematical correlation and build a calculation model for bucket tooth wear. When it is 180°, the two postures form a symmetrical state. , the model is simplified to a linear relationship , suitable for fast calculation; when the angle When it is 90°, the model passes The coefficient compensates for the influence of asymmetric posture to ensure the accuracy of the calculation results.

[0053] Through the above-mentioned technical solution, this application achieves high-precision dynamic calculation of bucket tooth wear, effectively resolving the problem of cumulative measurement errors caused by posture changes in traditional methods. This method can automatically adapt to different operating posture combinations and accurately convert spatial position deviations into radial wear through geometric relationship transformation, thus avoiding the subjective judgment errors in manual measurement. Furthermore, simplified calculation modes are preset for typical operating angles, significantly reducing the system's computational load while ensuring calculation accuracy, making it suitable for the real-time detection needs of construction machinery.

[0054] In this embodiment, step S6 includes: the control system compares the calculated current bucket tooth wear with the preset wear threshold; when the bucket tooth wear is greater than the preset wear threshold, the control system sends an alarm signal to the interactive system, and the interactive system displays an alarm prompt on the instrument interface to remind the operation and maintenance service personnel to replace the bucket teeth in time; when the bucket tooth wear is less than or equal to the preset wear threshold, the control system does not send an alarm signal.

[0055] The preset wear threshold is the maximum allowable wear threshold for the bucket teeth and is used to determine whether maintenance action is required. The alarm signal is triggered by automatically generating an alarm command when the detection value exceeds the threshold. This is achieved by the central processor executing logical judgments and sending command codes to the interactive system to ensure that abnormal conditions are promptly identified. The alarm prompt displayed on the instrument interface converts the alarm information into visual symbols or text, making it easier for operators to intuitively access the information.

[0056] Specifically, this solution achieves real-time monitoring of the wear status through a dynamic comparison mechanism. After calculating the bucket tooth wear, the control system automatically compares the value with a preset threshold. When the detection value exceeds the threshold, the central processing unit generates an alarm instruction and transmits it to the interactive system via the communication module. After receiving the instruction, the interactive system activates the preset alarm icon and text prompt on the instrument interface, which can also be accompanied by an audible warning. Based on the prompt information, the operator can immediately take maintenance measures such as replacing the bucket teeth. If the detection value does not exceed the threshold, the system only updates the wear display data without triggering the alarm process, maintaining normal operation. This process achieves closed-loop control through preset logical judgment conditions.

[0057] Through the above technical solution, this application solves the maintenance delay problem caused by the traditional detection method's reliance on manual experience and judgment, and establishes an automated wear status assessment system. When the bucket tooth wear reaches a critical state, the system immediately triggers the alarm mechanism, allowing maintenance personnel to replace components within the optimal time window to avoid equipment damage caused by excessive wear. At the same time, the silent state control mechanism ensures that the system will not generate false alarms under normal operating conditions, maintaining the continuity of the operation process. Through the synergistic effect of threshold judgment and alarm triggering, this solution achieves a seamless connection from wear detection to maintenance decision-making, significantly improving the timeliness and accuracy of equipment operation and maintenance.

[0058] Other structures and operations of the excavator bucket tooth wear detection system and method according to the embodiments of the present invention are well known to those skilled in the art and will not be described in detail here.

[0059] In the description of this specification, the reference terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" mean that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art can combine and combine different embodiments or examples described in this specification and features of different embodiments or examples without contradiction.

[0060] While 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 invention, and that the scope of the invention is defined by the claims and their equivalents.

Claims

1. An excavator bucket tooth wear detection system, characterized in that: include: sensor systems, control systems, and interactive systems; The sensor system and the interactive system are both signal-connected to the control system; The sensor system is used to acquire and transmit excavator posture information data to the control system in real time; The interactive system is used to send a bucket tooth wear detection enable signal and a bucket tooth wear calculation signal to the control system, display the current excavator posture information, bucket tooth wear amount information and guidance information on the instrument display, and issue an alarm prompt; On the one hand, the control system sends a guidance signal to the interactive system based on the bucket tooth wear detection enable signal, so that the operator controls the excavator bucket to complete two posture positioning in sequence according to the guidance information. On the other hand, the control system processes and stores the excavator posture information data in real time, and calculates the bucket tooth wear amount according to the bucket tooth wear calculation signal. The processed posture information and the calculated bucket tooth wear amount information are sent to the interactive system together; the control system determines whether to send an alarm signal to the interactive system based on the bucket tooth wear amount calculation result.

2. The excavator bucket tooth wear detection system according to claim 1, characterized in that: The control system includes a communication module, a central processing unit and a storage module. The communication module is used for receiving and sending data. The sensor system and the interactive system are both connected to the communication module signal. The central processing unit is used for data processing and calculation. The storage module is used to store control programs, data calculation algorithms and calculation result data.

3. The excavator bucket tooth wear detection system according to claim 2, characterized in that: The sensor system includes: a boom angle sensor, a dipper arm angle sensor, a bucket angle sensor and a slewing platform angle sensor. The four angle sensors are all connected to the communication module signal. The boom angle data, dipper arm angle data, bucket angle data and slewing platform angle data respectively obtained by the four angle sensors constitute the excavator posture information data.

4. A method for detecting bucket tooth wear of an excavator, characterized in that: The excavator bucket tooth wear detection system applied to any one of claims 1 to 3 above comprises: S1, angle data acquisition and processing; S2, operation-guided dual-posture positioning; S3, tooth tip theoretical position calculation; S4, tooth tip position difference calculation; S5, bucket tooth wear amount calculation; S6, over-threshold alarm.

5. The method for detecting bucket tooth wear of an excavator according to claim 4, characterized in that: Step S1 includes: Obtain the original angle data of the slewing platform, boom, arm, and bucket; Calibrate and calibrate the original angle data to obtain the joint angle data of the slewing platform, boom, arm, and bucket; Process the joint angle data using the Kalman filter algorithm; The processed joint angle data is sent to the interactive system.

6. The method for detecting bucket tooth wear of an excavator according to claim 4, characterized in that: Step S2 includes: controlling the excavator bucket to complete the first posture positioning according to the guidance information; The excavator bucket is controlled according to the guidance information to complete the second posture positioning.

7. The excavator bucket tooth wear detection method according to claim 6, characterized in that: Step S3 includes: The DH parameter method is used to define the base coordinate system, boom joint coordinate system, arm joint coordinate system, bucket joint coordinate system and bucket tooth endpoint coordinate system; Construct a kinematic model from the excavator's rotation center to the bucket tooth end point; Get the DH parameters and joint variables of the excavator working device: Substitute the DH parameters and joint variables of the excavator working device into the transformation matrix to obtain the transformation matrix from the base coordinate system to the bucket coordinate system; The theoretical coordinates of the bucket tooth tip in the base coordinate system are calculated based on the transformation matrix.

8. The method for detecting bucket tooth wear of an excavator according to claim 7, characterized in that: In the DH parameter method: the Z axis is the motion axis of the joint, the X axis is the common normal of two adjacent Z axes, and the Y axis is determined by the right-hand rectangular coordinate system composed of XYZ; In the base coordinate system, the excavator's rotation center is the origin; in the boom joint coordinate system, the hinge point between the boom and the turntable is the origin; in the arm joint coordinate system, the hinge point between the boom and the arm is the origin; in the bucket joint coordinate system, the hinge point between the arm and the bucket is the origin; in the bucket tooth endpoint coordinate system, the tip of the bucket tooth is the origin.

9. The method for detecting bucket tooth wear of an excavator according to claim 7, wherein: Step S4 includes: Verify whether the theoretical coordinates of the bucket tooth tip in the first and second postures satisfy the formula: Where, is the actual coordinate of the bucket tooth tip, is the theoretical coordinate of the bucket tooth tip in the first posture, is the theoretical coordinate of the bucket tooth tip in the second posture; If the theoretical coordinates of the bucket tooth tip in the first posture and the second posture satisfy the formula, the bucket tooth tip is not worn; If the theoretical coordinates of the bucket tooth tip in the first posture and the second posture do not satisfy the formula, the bucket tooth tip is worn. At this time, according to the position deviation vector: And the position deviation calculation formula: , calculate the theoretical position deviation of the bucket tooth tip after wear; Where, is the theoretical position deviation of the bucket tooth tip after wear, is the theoretical three-axis coordinate of the bucket tooth tip in the first posture, is the theoretical three-axis coordinate of the bucket tooth tip in the second posture, It is the difference between the theoretical three-axis coordinates of the bucket tooth tip in the first posture and the theoretical three-axis coordinates of the bucket tooth tip in the second posture.

10. The method for detecting bucket tooth wear of an excavator according to claim 9, wherein: Step S5 includes: According to the formula: , calculate the bucket tooth wear, where, is the bucket tooth wear, is the theoretical position deviation of the bucket tooth tip after wear, is the angle of the bucket joint in the two postures; when hour, , the formula can be simplified to: ; when hour, , the formula can be simplified to: .

11. The method for detecting bucket tooth wear of an excavator according to claim 10, wherein: Step S6 includes: The control system compares the calculated current bucket tooth wear with a preset wear threshold; When the bucket tooth wear exceeds the preset wear threshold, the control system sends an alarm signal to the interactive system, which displays an alarm prompt on the instrument interface to remind the operation and maintenance service personnel to replace the bucket teeth in time; When the bucket tooth wear is less than or equal to the preset wear threshold, the control system does not send an alarm signal.

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