Reasonability check

Abstract

A system is provided for determining the rationality of a current ground surface on which a construction machine is located in compliance with a previous measurement of the ground surface. The controller is provided with a digital model defined within a frame of reference external to the construction machine. The controller determines a current relative orientation and an expected relative orientation of at least one sensor pair of the plurality of distance sensors with respect to each other and with respect to a reference plane defined in a digital model. The controller compares the orientations to confirm whether the current relative orientation conforms to the expected relative orientation.

Description

Technical Field

[0001] This application relates to a construction machine and a method of operating the construction machine, the construction machine having work implements for working on the ground. Background Technology

[0002] The planning and implementation of building projects that generate design surfaces from existing ground surfaces have traditionally been carried out through a series of manually controlled operations. Such design surfaces can be milled surfaces generated during milling operations, or they can be paved surfaces produced during paving operations.

[0003] In the example of a road milling project, the ground area to be milled is first measured. This could be an initial measurement of an area for, for example, a road or airport to be built. This initial measurement dataset identifies a series of points on the ground, identified by their x, y, and z coordinates in a local ground-based reference system. Such measurements are typically taken and provided to planning authorities or design offices, which can use the initial measurements to plan the project. The appropriate "z" coordinate for each point is its actual elevation in the local ground-based reference system. This initial measurement dataset can also be referred to as the "actual ground dataset."

[0004] Planning bureaus or design offices can plan building projects and create project design datasets that include a dataset identifying the desired final ground elevation and the design surface dataset for the project to be built on the ground (e.g., paving or other structures). Part of this design work involves creating a description of the desired milled surface to be produced by a road milling machine. This desired surface can be identified using a design surface dataset that defines a series of desired milling points in an area, identified again by x, y, and z coordinates in a local ground-based reference system. The appropriate "z" coordinate for each point is the desired elevation of that point in the local ground-based reference system. The dataset is typically in the form of a set of triangles, each defined by absolute x, y, and z information, suitable for defining three angles in an external reference system independent of the milling machine. For an "actual ground dataset" defining the existing ground, the size of the triangles is typically on the order of millimeters to up to several inches. For a "design surface dataset," the triangles can be much larger, and can be larger than the milling machine, such that the milling machine will be positioned on a single triangle. The size of the triangles can vary within the same project, depending on the surface roughness. The rougher the surface, the smaller the triangle should be to produce the best representation of the actual surface. Scanning is a common method for measuring such actual surfaces.

[0005] Before commencing milling, the surveyor can return to the area to be milled and locate multiple points on the original ground, measuring these points to identify the x, y, and z coordinates of each point in a local ground-based reference system. The surveyor then calculates the required milling depth at each point based on data defining the desired milling surface and data defining the actual ground. The surveyor can physically write the desired milling depth on the ground near the marked point, such as with a can of spray paint. The mark is typically a spray-painted "X" with a spray-painted number next to it indicating the desired milling depth at that location.

[0006] The milling machine operator then observes the desired milling depth written on the ground and adjusts the milling depth accordingly upon reaching that point. The operator controls the desired milling depth at each end of the milling drum by inputting this depth (e.g., 2.0) into a slope control system (e.g., the LevelPro control system developed by the applicant, Wirtgen GmbH). Alternatively, the operator can input the desired milling depth at one end of the milling drum plus the desired lateral slope of the milling drum. The slope control system then maintains the selected milling depth using any of several combinations of available input sensors, typically two sensors selected from a left side plate sensor, a right side plate sensor, and a gravity-based lateral slope sensor. Other sensors may also be used.

[0007] Attempts have been made to partially automate this process. One such attempt can be found in Snoeck's U.S. Patents Nos. 8961065 and 9039320. In the Snoeck patent, the actual elevation of the bottom of the milling drum at each end is determined, and then the actual elevation of the bottom of the milling drum at each end is controlled based on a comparison with the design elevation of a design surface at a location suitable for milling the drum at each end.

[0008] There is a continuous need for improvements to such automated systems. Summary of the Invention

[0009] One problem with this type of automation system is the error in the digital model used to guide the automated operation of construction machinery. In order for the digital model to accurately guide the automated operation of construction machinery, the current ground on which the construction machinery is operating needs to be the same as the actual ground described in the "actual ground dataset" determined in the initial measurements.

[0010] This disclosure recognizes that the description of the actual ground in the "actual ground dataset" determined in the initial measurements may contain errors compared to the actual ground encountered by construction machinery when it is working on the ground. Such errors can arise in several ways, including:

[0011] 1. Incorrect measurements taken during the initial investigation;

[0012] 2. Modifications made to the ground after the initial measurements;

[0013] 3. Debris, such as dirt or milling material, that accumulates on the ground after the initial measurement;

[0014] 4. Incorrect sensor placement, for example, the sensor operating on the wrong surface; and

[0015] 5. The sensor used when the task was completed malfunctioned.

[0016] This disclosure provides methods and systems for confirming whether the current ground encountered by construction machinery during ground operations is consistent with the ground expected based on an “actual ground dataset” determined in initial measurements.

[0017] Using construction machinery, the construction machinery including a mechanical frame, working implements supported from the mechanical frame, a controller, and a plurality of distance sensors directly or indirectly supported from the mechanical frame, each corresponding distance sensor being configured to detect the distance between the mechanical frame and the ground, the method includes:

[0018] The controller is provided with a digital model defined in a reference frame outside the construction machinery, the digital model being configured to guide the construction machinery as it processes the ground to generate a design surface;

[0019] The controller determines the current position of the first and second sensors of at least one sensor pair among the plurality of distance sensors relative to each other and relative to a reference plane defined within the digital model.

[0020] Relative orientation;

[0021] The controller is used to determine, at least in part, the expected relative orientation of the first and second sensors of the at least one sensor pair relative to each other and relative to the reference plane, based on the digital model.

[0022] as well as

[0023] The controller is used to compare the current relative orientation of the at least one sensor pair with the expected relative orientation to confirm whether the current relative orientation matches the expected relative orientation.

[0024] The construction machinery may further include at least one position data determining component operable to determine position data, thereby defining the current position of a reference point on the construction machinery in a reference frame outside the construction machinery, and the method may further include receiving position data using a controller and determining the current x, y position of each distance sensor in a reference frame outside the construction machinery using the controller.

[0025] As further explained below, a digital model may include two or more of several possible datasets. These datasets may include: (1) an “actual ground dataset”; (2) an “operational depth dataset”; and / or (3) a “design surface dataset”. The “actual ground dataset” may include x, y, and z coordinate data describing the actual ground previously measured in a reference frame outside the construction machinery, and the “actual ground dataset” may be updated from time to time to reflect corrections to the original dataset. The “operational depth dataset” may include x and y coordinate data in a reference frame outside the construction machinery and operation depth data corresponding to the x and y coordinate data. The “design surface dataset” may define the design surface to be created and may include x, y, and z coordinate data of the design surface in a reference frame outside the construction machinery. The “design surface dataset” may also be prepared in different formats, for example, using x and y coordinate data to define the centerline of a road, and then defining the width and lateral slope of the road corresponding to each point along the centerline. Other formats may be used for any dataset, depending on the nature of the design surface being constructed.

[0026] In one embodiment, the digital model may be a job depth model, which includes a job depth dataset and a design surface dataset.

[0027] In another embodiment, the digital model may be an operational elevation model, which includes an actual ground dataset and a design surface dataset.

[0028] In another embodiment, the digital model may include an actual ground dataset and an operational depth dataset.

[0029] In one embodiment, the reference plane of the digital model may be a horizontal reference plane, which is defined as a reference plane perpendicular to the direction of gravity in a reference frame outside the construction machinery.

[0030] In one embodiment, the method may further include using at least one slope sensor to detect the slope of the mechanical frame relative to the direction of gravity and therefore relative to a reference plane.

[0031] In one embodiment, the method may further include using a longitudinal slope sensor to detect the longitudinal slope of the mechanical frame relative to the direction of gravity, and using a lateral slope sensor to detect the lateral slope of the mechanical frame relative to the direction of gravity, the lateral slope being perpendicular to the longitudinal slope.

[0032] In the method of initiating verification, the comparison can be performed before starting work on the ground with the work equipment to determine whether the current relative orientation of the at least one sensor pair is consistent with the digital model.

[0033] In the method of verification during operation, the comparison can be performed during the operation of the work equipment on the ground to determine whether the current relative orientation of at least one sensor pair is consistent with the coordinate data describing the expected ground in a reference frame outside the construction machinery. The expected ground may or may not be modified compared to the original ground measured for the actual ground dataset.

[0034] In one embodiment, when determining the current relative orientation and expected relative orientation of at least one sensor pair, the at least one sensor pair may include multiple sensor pairs.

[0035] In another embodiment, the comparison may include determining whether the lack of consistency between the current relative orientation and the expected relative orientation of any sensor pair is due to changes in the ground after the preparation of the digital terrain model or due to sensor malfunction.

[0036] In the above embodiments, the comparison may include identifying a faulty sensor as one that is present in all sensor pairs where the current relative orientation of the corresponding sensor pair is inconsistent with the expected relative orientation, and not present in all sensor pairs where the current relative orientation of the corresponding sensor pair is inconsistent with the expected relative orientation.

[0037] In the two embodiments just above, if the comparison determines that the lack of consistency between the current relative orientation and the expected relative orientation of any sensor pair is due to changes in the ground after the preparation of the digital model, the digital model can be updated to reflect that change.

[0038] In the three embodiments just mentioned above, if a comparison determines that the lack of consistency between the current relative orientation and the expected relative orientation of any sensor pair is due to a sensor malfunction of the distance sensor used to control the working depth of the work implement, the controller can automatically switch the control of the working depth from the faulty sensor to a different sensor.

[0039] In any of the above embodiments, determining the current relative orientation using the controller may include determining the difference between the current distance between the first sensor and the reference plane detected by the first sensor of the at least one sensor pair and the current distance between the second sensor and the reference plane detected by the second sensor of the at least one sensor pair, or alternatively, determining the current relative orientation using the controller may include determining the current angle of the line between the ground contact point of the first sensor and the ground contact point of the second sensor of the at least one sensor pair relative to the reference plane.

[0040] In another embodiment, the construction machinery may include a mechanical frame and a working device supported from the mechanical frame for performing work on the ground as the machinery moves across the ground during operation. A plurality of distance sensors may be supported directly or indirectly from the mechanical frame, each respective distance sensor configured to detect the distance between the mechanical frame and the ground. At least one slope sensor may be configured to detect the slope of the mechanical frame relative to the direction of gravity. At least one position data determination component may be operable to determine position data to define the current position of a reference point on the construction machinery in a reference frame external to the construction machinery. A controller is associated with a memory storing a digital model defined in the reference frame external to the construction machinery, the controller being operable to receive the position data from the at least one position data determination component, wherein the controller is configured to:

[0041] Determine the current x and y positions of each distance sensor in a reference frame outside the construction machinery;

[0042] Determine the current relative orientation of the first and second sensors of at least one sensor pair among the plurality of distance sensors relative to each other and relative to a reference plane defined within the digital model;

[0043] The first sensor of the at least one sensor pair is determined at least in part based on the digital model.

[0044] The expected relative orientation of the second sensors relative to each other and relative to the reference plane;

[0045] The current relative orientation of the at least one sensor pair is compared with the expected relative orientation to confirm the...

[0046] Whether the current relative orientation conforms to the expected relative orientation; and

[0047] In the event that the current relative orientation of any sensor pair is inconsistent with the expected relative orientation, a correction action is provided in response to the lack of consistency.

[0048] In one embodiment, the digital model of the construction machinery may be an operational depth model that includes an operational depth dataset and a design surface dataset.

[0049] In another embodiment, the digital model of the construction machinery may be an operational elevation model that includes an actual ground dataset and a design surface dataset.

[0050] In another embodiment, the digital model of the construction machinery may include an actual ground dataset and an operational depth dataset.

[0051] In any of the above embodiments of the construction machinery, the reference plane within the digital model can be a horizontal reference plane, which is defined as a reference plane perpendicular to the direction of gravity in a reference frame outside the construction machinery.

[0052] In any of the above embodiments of the construction machinery, the at least one slope sensor may include a longitudinal slope sensor and a lateral slope sensor, the longitudinal slope sensor being configured to detect the longitudinal slope of the mechanical frame relative to the direction of gravity, and the lateral slope sensor being configured to detect the lateral slope of the mechanical frame relative to the direction of gravity, the lateral slope being perpendicular to the longitudinal slope.

[0053] In any of the above embodiments of the construction machinery, the construction machinery may include a plurality of tracked ground engagement units supporting a mechanical frame from the ground, and at least one inclination sensor may include a track angle sensor configured to detect the tilt angle of at least one tracked ground engagement unit relative to the mechanical frame.

[0054] Many objects, features, and advantages of the embodiments set forth herein will readily become apparent to those skilled in the art when the following disclosure is read in conjunction with the accompanying drawings. Attached Figure Description

[0055] Figure 1 This is a left-side view of a construction machine implemented as a road milling machine in accordance with the present invention.

[0056] Figure 2 yes Figure 1 A schematic left-hand view of a road milling machine performing a milling operation, with the rear track of the road milling machine running in the milling track.

[0057] Figure 3 When performing the first milling operation Figure 2 A schematic rear view of the machine.

[0058] Figure 4 yes Figure 3 A schematic rear view of the machine performing a second milling operation adjacent to the first milling operation.

[0059] Figure 5 It is a schematic plan view of the ground that has been milled in the first and second milling operations.

[0060] Figure 6 This is a schematic rear view of the milling machine on top of the ground to be milled, indicating the design profile of the design surface below the ground. The design elevations at the current x, y positions at the left and right ends of the milling drum and at a midpoint of the milling drum are indicated by circles "X". Figure 6 In the case shown, the design surface profile under the milling drum is straight, and the three "X"s are aligned.

[0061] Figure 7 This is a schematic rear view of a milling machine on top of the ground to be milled, showing the design outline of the design surface below the milled surface. Figure 7 In the case shown, the design surface profile below the milling drum includes a crown.

[0062] Figure 8 Is Figure 7 The view shows the design elevations at the current x, y positions of the left and right ends of the milling drum and a midpoint of the milling drum, indicated by circles "X". Figure 8 In the case shown, the design surface profile below the milling drum includes a crown, and the three "X"s are misaligned.

[0063] Figure 9 It is similar to Figure 8 The view shows the position of the crown with an additional circle "X", which is now aligned with the "X" that fits the midpoint and the "X" that fits the right end of the milling drum.

[0064] Figure 10 Is Figure 1-9 A schematic diagram of a controller with relevant sensor inputs and control outputs in an embodiment of a milling machine.

[0065] Figure 11 This is a schematic diagram of the control panel of the controller associated with the slope control system of the milling machine.

[0066] Figure 12 It is similar to Figure 6-9 Another schematic diagram, but it illustrates a technique for identifying discontinuities in the design surface of a planned path adjacent to a milling machine.

[0067] Figure 13 This is a right-side perspective view of a construction machine that incorporates the asphalt paver of the present invention.

[0068] Figure 14 It is for performing paving operations. Figure 13A schematic right-side view of a paver.

[0069] Figure 15 yes Figure 14 A schematic rear view of the machinery performing the first paving operation.

[0070] Figure 16 yes Figure 14 A schematic rear view of the machinery performing a second paving operation adjacent to the first paving operation.

[0071] Figure 17 It is a schematic plan view of the ground that has been paved in the first and second paving operations.

[0072] Figure 18 It is a schematic rear view of the paver on top of the ground to be paved, and indicates the design outline of the designed paving surface formed above the ground, wherein the designed surface includes the crown.

[0073] Figure 19 This is a schematic diagram of a controller with relevant sensor inputs and control outputs in one embodiment, configured to confirm whether the current ground conforms to the ground as previously measured.

[0074] Figure 20 This is a schematic diagram of a scanning type distance sensor.

[0075] Figures 21A-21C This is a schematic diagram illustrating a method for confirming whether the current ground conforms to the previously measured ground.

[0076] Figure 22 This is a schematic diagram for determining the current relative orientation of a sensor pair, represented as the angle between the sensor elements and the reference plane. Detailed Implementation

[0077] The following disclosure describes several embodiments of construction machinery having work implements for operating on surfaces. (As per...) Figure 1-12 In one described embodiment, the construction machinery may be a road milling machine, wherein the working implement is a milling drum. (As per...) Figure 13-18 In another embodiment described, the construction machinery may be an asphalt paver, wherein the working implement is a paving screed. The construction machinery may also be a concrete paver, wherein the working implement is a slipform paver mold. The construction machinery may also be a road grader, wherein the working implement is a grader blade.

[0078] This disclosure relates to improvements to a system for automatically controlling construction machinery when it operates on the ground to generate a designed surface. In the case of a milling machine, the designed surface can be a milled surface produced by removing material from the original ground. In the case of a paver, the designed surface can be a paved surface generated by adding material on top of the original ground.

[0079] The disclosure also involves several types of digital models configured to guide construction machinery as it operates on the ground to create the designed surface.

[0080] This document describes in detail such a digital model, which may be referred to herein as an operation depth model, and was originally disclosed in U.S. Patent Application Serial No. 17 / 725,640, filed April 21, 2022, as described in U.S. Patent Publication No. 2023 / 0340736, which is incorporated herein by reference. The operation depth model may include an "operation depth dataset" and a "design surface dataset." The "operation depth dataset" includes x and y coordinate data in a reference frame outside the construction machinery, and includes expected operation depth data corresponding to the x and y coordinate data. The "design surface dataset" defines the design surface to be generated and includes x, y, and z coordinate data of the design surface in a reference frame outside the construction machinery.

[0081] Another such digital model, which may be referred to herein as an operational elevation model, is found in Snoeck's U.S. Patents 8,961,065 and 9,039,320. In Snoeck's patents, the actual elevation of the bottom of the milling drum at each end is determined, and then the actual elevation of the bottom of the milling drum at each end is controlled based on a comparison with the design elevation of a design surface at the location of each end of the milling drum. Such an operational elevation model may include an "actual ground dataset" and a "design surface dataset." The "actual ground dataset" includes x, y, and z coordinate data describing the previously measured actual ground in a reference frame outside the construction machinery.

[0082] The third such digital model can include both "actual ground datasets" and "operational depth datasets".

[0083] External reference systems for construction machinery can be, for example, satellite-based systems such as the Global Positioning System (GPS) or the Global Navigation Satellite System (GNSS). Other external reference systems may include laser-based mechanical total stations.

[0084] When using one of the satellite-based systems, it is known that while x and y position data from such a system can be very accurate in determining horizontal positions on Earth, the "z" or vertical position data is less accurate than the "x" and "y" position data. For this reason, the digital model described in this paper can determine a more accurate vertical position by directly measuring the vertical position with reference to existing ground that has already been measured.

[0085] Figure 1-18 The following description describes the use of the working depth model to guide construction machinery on its generated design surface.

[0086] Figure 1-18 Job depth model:

[0087] Now refer to the attached diagram, especially the reference... Figure 1 The diagram shows a construction machine in the form of a road milling machine, generally designated by the numeral 10. Machine 10 includes a machine frame 12. Multiple ground engagement units 14, shown in track form, support machine 10 from the ground 16. Wheeled ground engagement units may also be used. The ground engagement units 14 include two front ground engagement units 14LF and 14RF, and two rear ground engagement units 14LR and 14RR. Multiple lifting columns 17 support the machine frame 12 from the ground engagement units 14 in an adjustable elevation manner.

[0088] The milling drum housing 20 is supported by the mechanical frame 12. The rotatable milling drum 22 is received at least partially by the milling drum housing 20 and also supported by the mechanical frame 12. Therefore, the height of the mechanical frame 12 and the milling drum 22 relative to the ground 16 can be adjusted by adjusting the extension of the lifting column 17. On its left and right sides, the milling drum housing 20 is closed by a left height-adjustable side plate 24 and a right height-adjustable side plate 26 located near the left end 28 and right end 30 of the milling drum 22. A height-adjustable scraper 29 can close the rear of the milling drum housing 20.

[0089] Figure 1 The earthmoving machinery 10 shown is of the type commonly referred to as a large front-loading milling machine, which also includes a first conveyor section 32 and a second conveyor section 34 for conveying the milled material away from the milling drum 22. An operator's station 36 may be mounted on the machine frame 12, and a control panel 38 may be located at the operator's station 36. A main engine 40, which may be in the form of a diesel internal combustion engine or any other suitable power source, is located at the rear of the operator's station 36. A direct belt drive (not shown) may connect the engine 40 to the milling drum 22 in a known manner. The direct belt drive may be located in the belt housing section 42.

[0090] Construction machinery 10 may carry at least one position data determining component 44 and 46, supported from the machinery frame 12 and operable to determine position data, thereby defining the current position of a reference point on the machinery in a reference frame external to the construction machinery. In one embodiment, the at least one position data determining component comprises at least two position data determining components 44 and 46 in the form of a Global Navigation Satellite System sensor (e.g., a GPS sensor). In another embodiment, the position data determining components 44 and 46 may be reflectors configured for use with a laser-based mechanical total station. By including at least two such position data determining components, the azimuth of the two position data determining components allows for the determination of the corresponding positions of all points on the machinery 10. Figure 1 and 10 The diagram schematically illustrates the x, y, and z components of this reference frame outside the milling machine. The x and y positions can represent positions in the horizontal plane, while the z position can represent the vertical position relative to the horizontal plane. Figure 1 In the diagram, the x-direction is shown as corresponding to the forward direction of the milling machine, but this is purely coincidental and not necessary.

[0091] Controller:

[0092] Position signals from sensors 44 and 46 can be received in the controller 48 of the construction machinery 10, such as Figure 10 As schematically shown. The controller 48 described herein is used with the road milling machine 10 to control the milling depth of the milling drum during milling operations. This generally refers to the control of the working depth of the work implement during operation, and it is understood that it also applies to the references below. Figure 13-18 The described embodiments of the asphalt paver are referenced in the following text. Figure 13-18 In the embodiments of the described asphalt paver, the controller controls the paving depth, i.e., the paving thickness, of the paving screed during paving operations.

[0093] The controller 48 can also receive signals from height sensors 50 and 52, respectively associated with the left side plate 24 and the right side plate 26, corresponding to the actual milling depths of the left end 28 and the right end 30, respectively. Height sensors 50 and 52 may be integrated, for example, with a hydraulic smart cylinder that supports the side plates 24 and 26 relative to the mechanical frame 12. The controller 48 can also receive signals from a gravity-based slope sensor 54 indicating the lateral slope of the mechanical frame 12. As further explained below, the controller 48 can actuate command signals to the left and right lifting columns, such as the left rear lifting column 17 and the right rear lifting drop 17, to adjust the actual milling depths of the left end 28 and the right end 30 of the milling drum 22.

[0094] like Figure 10As schematically shown, construction machinery 10 includes a control system 56, which includes a controller 48. The controller 48 may be part of the mechanical control system of construction machinery 10, or it may be a separate control module. The controller 48 may, for example, be mounted in a control panel 38 located at an operator station 36. The controller 48 is configurable to receive input signals from various sensors, such as sensors 44, 46, 50, 52, and 54 already described. The signals transmitted from the various sensors to the controller 48 are... Figure 10 The diagram illustrates the lines connecting the sensor to the controller, with arrows indicating the signal flow from the sensor to the controller 48.

[0095] Similarly, controller 48 will generate control signals for controlling the operation of various actuators, such as the lifting column 17 associated with the rear ground engagement units 14LR and 14RR, these control signals in Figure 10 The diagram schematically indicates the connection of controller 48 to various actuators, with arrows indicating the flow of command signals from controller 48 to the corresponding actuators. It will be understood that, in order to control a hydraulic cylinder-type actuator, controller 48 can send electrical signals to an electro / mechanical control valve (not shown) that controls the flow of hydraulic fluid to and from the hydraulic cylinder.

[0096] Controller 48 includes or may be associated with processor 58, computer-readable medium 60, database 62, and input / output module or control panel 38 having display 64. Input / output devices 66, such as keyboard, joystick, or other user interfaces, are provided to allow an operator to input commands to the controller. It should be understood that controller 48 as described herein may be a single controller having all the described functions, or it may include multiple controllers, wherein the functions are distributed among the multiple controllers.

[0097] The various operations, steps, or algorithms described in conjunction with controller 48 can be directly embodied in hardware, computer program product 68 (such as software modules executed by processor 58), or a combination of both. Computer program product 68 can reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, removable disk, or any other form of computer-readable medium 60 known in the art. Exemplary computer-readable medium 60 can be coupled to processor 58, allowing the processor to read information from and write information to the memory / storage medium. Alternatively, the medium can be integrated into the processor. The processor and medium can reside in an application-specific integrated circuit (ASIC). The ASIC can reside in the user terminal. Alternatively, the processor and medium can reside as discrete components in the user terminal.

[0098] As used herein, the term "processor" can refer to a processing device and / or logic for at least a general or special purpose, as understood by those skilled in the art, including but not limited to microprocessors, microcontrollers, state machines, etc. A processor can also be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, multiple microprocessors, one or more microprocessors combined with a DSP core, or any other such configuration.

[0099] Control panel 38 may include, for example, the control panel of the slope control system 72 of the milling machine 10, such as... Figure 11 The slope control system 72 is schematically illustrated. For example, it may be the LevelPro slope control system developed by the applicant of this application, Wirtgen GmbH. Further description of such a slope control system 72 can be found in U.S. Patent No. 7,946,788, the details of which are incorporated herein by reference. The operator of the milling machine can control the desired milling depth at each end 28 and / or 30 of the milling drum 22 by inputting the depth (e.g., 2.0″) into the slope control system 72. Alternatively, the operator can input the desired milling depth at one end of the milling drum plus the desired lateral slope of the milling drum. Figure 11 A control panel 38 is shown, through which an operator can input settings for the milling depth and / or the lateral tilt angle of the milling drum, suitable for the end of the milling drum. As further explained in U.S. Patent No. 7,946,788, the center input device 78 can be formatted for inputting the lateral slope or the left or right milling depth. The left input device 74 can be formatted for inputting the left milling depth or lateral slope. The right input device 76 can be formatted for inputting the right milling depth or lateral slope. As further described below, the invention can automatically generate inputs for the desired milling depth and / or lateral slope and input these values ​​into the slope control system 72. The slope control system 72 then uses any of several combinations of available input sensors to maintain the selected milling depth; the available input sensors are typically two sensors selected from the left side plate sensor 50, the right side plate sensor 52, and the gravity-based lateral slope sensor 54.

[0100] Constructing a deep digital model of the task:

[0101] When planning road milling or other construction projects, the ground area to be milled can be measured. This could be, for example, an initial measurement of an area where a road or airport will be built. This initial measurement dataset identifies a series of points on the ground 16, identified by their x, y, and z coordinates in a local ground-based reference system. This measurement is provided to a planning bureau or design office, which can use the initial measurement to plan the project. The appropriate "z" coordinate for each point is its actual elevation in the local ground-based reference system.

[0102] Planning bureaus or design offices can plan building projects and create project design datasets, which include a design surface dataset identifying the desired final elevation of the ground and the project to be built on the ground (e.g., paving or other structures). Part of this design work is creating a description of the desired milled surface to be produced by a road milling machine. This desired surface can be identified by a design surface dataset that defines a series of desired milling points in an area, which are again identified by x, y, and z coordinates in a local ground-based reference system. The “z” coordinate suitable for each point is the desired elevation of that point in the local ground-based reference system. The datasets are typically in the form of a set of triangles, each defined by absolute x, y, and z information used to define three angles in an external reference system independent of the milling machine. For an “actual ground dataset” that defines the existing ground, the size of the triangles is typically on the order of millimeters to up to several inches. For a “design surface dataset,” the triangles can be much larger and can be larger than the milling machine, such that the milling machine will be positioned on a single triangle.

[0103] In one embodiment, a milling depth dataset can be created, containing x, y, and milling depth data. This can be used... Figure 10 The separate processor 70 (i.e., not the processor 58 located on the milling machine 10) shown schematically is prepared and can be prepared before the milling depth dataset is loaded on the controller 48 of the milling machine 10. The milling depth dataset is not created in real time during the milling operation.

[0104] Therefore, for example, a planning bureau creating a design surface dataset describing the desired milling surface can create a milling depth dataset by comparing an initial measurement dataset (“actual ground dataset”) with the design surface dataset describing the desired milling surface. Similarly, a milling depth dataset can be created at or near the work site by comparing an initial measurement dataset with the design surface dataset describing the desired milling surface 82. It should also be noted that the milling depth dataset can be updated during the milling operation. For example, it can be decided to perform the desired milling operation in two cuts instead of one. Thus, if the initial milling depth is 4 cm at a specific x, y orientation, it may be desired to perform two passes, each approximately 2 cm. The first pass can be performed at a first milling depth of less than 4 cm. The controller can then update the milling depth dataset by subtracting the initial cut depth from the initial milling depth. Then, in the second pass, the updated milling depth dataset will be used to control the cut to the final total desired milling depth.

[0105] Similarly, the planning authority can create a paving depth dataset to describe the paving layers to be created on the ground to create the final paved surface. The paving layers can, for example, be placed on a previously milled surface. Thus, in the first case, a design surface dataset defining the milled surface to be created can exist, while in the second case, a second design surface dataset describing the paving surface to be formed on top of the milled surface can exist. The paving depth dataset can be in the form of x, y, and paving depth data.

[0106] It should be understood that the local ground-based coordinate system (in which the initial measurement and design surface dataset is created) may not be the same coordinate system as the global navigation satellite system (in which sensors 44 and 46 operate), but the correlation between the position in the local ground-based coordinate system and the position in the global navigation satellite system is known, and one or other datasets may be transformed as needed to compare the signals with the signals in the selected reference frame of the sensors 44 and 46 used.

[0107] The working depth digital model, including the milling depth dataset and the design surface dataset, can then be loaded into the memory 60 of the controller 48 on the milling machine 10. The milling depth dataset and the design surface dataset can be loaded into the memory 60 of the milling machine 10 via a wireless connection. Alternatively, the milling depth dataset and the design surface dataset can be loaded into the memory 60 of the milling machine 10 by placing them on a portable data storage device such as a memory stick and then transferring the data from the portable data storage device to the memory 60 of the milling machine 10. This can be described as providing the milling depth dataset and the design surface dataset to the controller 48. As used herein, "providing" the dataset to the controller 48 includes in any way making the dataset accessible to the controller 48, and the dataset does not necessarily need to be stored in memory integrated with the controller.

[0108] There is no need to provide an initial measurement dataset (“actual ground dataset”) to the controller 48 of the milling machine 10.

[0109] In one embodiment, a separate processor 70 may be associated with an online portal created as a service for the owner / operator of the milling machine 10. The machine owner / operator and / or surveyors and / or planning bureaus working with the machine owner may upload their measurement datasets (“actual ground datasets”) and design surface datasets to the online portal. The separate processor 70 may then create and format the milling depth dataset and design surface dataset for use with the milling machine 10. When the owner / operator of the milling machine 10 is ready to perform milling operations, the milling depth dataset and design surface dataset can be wirelessly downloaded from the separate processor 70 in the online portal to the controller 48 of the milling machine 10.

[0110] The road milling machine 10 can then perform operations such as Figures 2-5 The diagram illustrates a ground milling operation. The road milling machine 10 may be equipped with GPS or other GNSS sensors 44 and 46, which are used to determine the orientation of the milling machine as it moves across the ground 16. More specifically, the GNSS system can determine the x, y position of each end 28 and 30 of the milling drum 22 in a reference system (e.g., the global positioning coordinate system of a GPS system) outside the milling machine 10. The x, y positions of the ends 28 and 30 of the milling drum 22 can be correlated with the x, y positions of a milling depth dataset and a design surface dataset. Based on the x, y positions of the ends 28 and 30 of the milling drum 22 detected by sensors 44 and 46, the controller 48 can determine the desired milling depth and desired lateral slope at each end of the milling drum, and these input values ​​can be fed to the slope control system 72 of the milling machine 10.

[0111] Based on the x and y positions of the left end 28 of the milling drum 22, the controller 48 can find the desired milling depth at that position in the (x, y, milling depth) dataset and feed the value to the left milling depth input 74 of the slope control system 72.

[0112] Based on the x and y positions of the right end 30 of the milling drum 22, the controller 48 can look up the desired milling depth at that position in the (x, y, milling depth) database and feed the value to the right milling depth input 78 of the slope control system 72.

[0113] Based on the x, y positions of the left end 28 and right end 30 of the milling drum 22, and optionally based on at least one point between the left and right ends, the controller 48 can look up the design elevation at each of those points in the design surface database and determine the design lateral slope, and can feed this value to the lateral slope input 76 of the slope control system 72. The desired lateral slope for any given orientation of the milling drum 22 (which corresponds to any given x, y position of the left end 28 and right end 30 of the milling drum 22) can be determined in several ways, as referenced below. Figure 6-9 As further described.

[0114] Figure 5 The diagram schematically illustrates the plan view of the "first pass" milling operation and the overlapping "second pass" milling operation. The "first pass" is indicated by the shaded area with "1" in the arrow. The "second pass" is indicated by the shaded area with "2" in the arrow. Figure 3 This is a schematic rear cross-sectional view of the milling machine 10 during the "first pass". Figure 4 This is a schematic rear cross-sectional view of the milling machine 10 during the "second pass".

[0115] In such Figure 3 In the typical “first pass” milling operation shown, the milling machine 10 can begin on the uncut actual surface 16, with side plates 24 and 26 resting on the uncut surface 16. First, the milling machine operator can “zero” the slope control system 72. This is achieved by lowering the mechanical frame 12 and the milling drum 22 until the milling drum 22 first contacts the surface 16 to be milled. This arrangement of the extension of the lifting column 17 and this position of the side plates 24 and 26 is set to a “zero” milling depth.

[0116] The slope control system 72 then uses any of the many possible combinations of sensor inputs to perform actual milling depth control for the desired milling depth. For example, the slope control system 72 can use two side plate sensors 50 and 52, or it can use a lateral slope sensor 54 and one of the side plate sensors 50 or 52. Other slope sensors, such as ultrasonic or laser sensors (not shown), may also be used if available.

[0117] In such Figure 3 After the "first pass" milling operation shown, the milling machine 10 can, as shown, perform... Figure 4 The observed "second pass" mode operation does not involve any quantified milling depth control. In a typical "second pass" milling operation, the right side plate 26 is allowed to run on the previous cut surface 80 from the "first pass," and the milling depth at the right end of the milling drum is set to zero to match the previous cut surface 80. The slope control system 72 can then use a gravity-based lateral slope sensor 54 to control the actual lateral slope to the desired lateral slope.

[0118] Determining the desired lateral slope:

[0119] For any given x, y position of the two ends 28 and 30 of the milling drum 22, the desired lateral tilt angle suitable for the milling drum 22 can be determined by knowing the elevation of the design surface at these two positions, provided that the design surface is planar between these two positions. However, it is possible that the design surface may have a “crown,” shoulder, or other discontinuity between these two positions, in which case the lateral slope determined solely by comparing the two end positions may be erroneous. This problem can be solved by including at least one midpoint between the two ends 28 and 30 in the lateral slope analysis. This midpoint can be, for example, the midpoint between the two ends. This process is carried out in... Figures 6-9 It is shown schematically in the diagram.

[0120] In addition, such as Figure 12 As schematically illustrated, the design elevation along a line in the x, y plane can be analyzed to obtain a point located laterally outside the end of the milling drum, thus identifying the presence of nonlinearities in the design surface of the planned path immediately adjacent to the milling machine. This allows the machine operator to potentially modify the planned path to improve milling efficiency. Furthermore, the machine operator can select different sensors to guide milling depth control.

[0121] Figure 6A rear view of the milling machine 10 standing on existing ground 16 is schematically shown. The design surface below is schematically represented by 82. The point on design surface 82 below the left end 28 of the milling drum 22 is indicated by an "X" numbered 84. The point on design surface 82 below the right end 30 of the milling drum 22 is indicated by an "X" numbered 86. The point on design surface 82 below the midpoint of the milling drum 22 is indicated by an "X" numbered 88. The controller 48 is configured to compare points 84, 86, and 88 and determine whether they are on a straight line. If they are on a straight line, this indicates that there is no "crown" between the endpoints and the desired lateral slope is the slope of the line passing through the three points.

[0122] Figure 7 The rear view of the milling machine is schematically shown, but this time it is positioned above a portion of the design surface 82, including the crown 90. Figure 8 The diagram schematically illustrates the comparison of these three points by controller 48, which will determine that the three points are not on a straight line. Once controller 48 determines that the three points are not on a straight line, the next step is to determine the orientation of the crown 90. This can be done by checking the intermediate point inward from one of the outer points 84 and 86 until the design elevation aligned with the other endpoint and the intermediate point 88 is found. Figure 9 The process is illustrated, where the left point 84 has moved inward until it is located at the crown point 90, where three points 84, 86, and 88 are found to be in a straight line. For Figure 9 In the example seen, the desired lateral slope is determined as the slope of the line passing through the three points 84, 86, and 88.

[0123] Controller 48 can also be configured to select the slope relative to the left side of the crown 90 as the design slope. In a similar manner... Figure 7-9 In this case, the controller can be configured to select the desired lateral slope as the slope of the longest length below the milling drum 22, which in Figure 9 In the example, the slope is on the right side of the crown 90. Controller 48 can also be configured to select one of the slopes adjacent to the previously milled portion, or controller 48 can be configured such that the slope on the right or left side of the crown 90 can be selected by the operator.

[0124] Figure 12An alternative is schematically illustrated, which checks the design elevation of a point located laterally outside the length of the milling drum 22 along a line defined by the x, y positions of both ends of the milling drum. In the illustrated embodiment, the controller can be configured to check the design milling depth elevation along a line extending between the x, y positions relative to the left lateral spacing distance 92 and the x, y positions relative to the right lateral spacing distance 94 of the milling drum 22. Distances 92 and 94 can, for example, range from 0 to 3 meters. This can be done in a manner similar to that described above for... Figure 7-9 The described method compares the design surface elevations 96 and 98 at the x and y positions with the design surface elevation 88 at the midpoint on the milling drum 22. In this way, the controller 48 can identify the orientation of crowns or other discontinuities 90 falling within a lateral distance 94 relative to the right side of the milling drum 22. This information can be displayed to the operator and / or used by the controller 48 to modify the planned path of the milling machine 10 or to select different sensors to guide milling depth control.

[0125] Operating instructions:

[0126] A detailed example of this operating method is described in the section on using a road milling machine 10 to control the milling depth of the milling drum during milling operations. As previously mentioned, this can be more generally referred to as controlling the working depth of the work implement during operation, and it will be understood that it also applies to embodiments of asphalt pavers, where the controller controls the paving depth, i.e., the paving thickness, of the paving screed during paving operations.

[0127] A method for controlling construction machinery 10, the construction machinery including a mechanical frame 12, a milling drum 22 supported by the mechanical frame 12, and a controller 48 configured to control the milling depth of the milling drum 22 when the construction machinery moves across ground 16, the method may include:

[0128] (a) Provide the controller 48 with a milling depth dataset, which includes x and y coordinate data in a reference frame outside the construction machinery, and includes expected milling depth data corresponding to the x and y coordinate data;

[0129] (b) Provide the controller 48 with a design surface dataset that defines the design surface to be created, which includes x, y, and z coordinate data of the design surface in a reference system outside the construction machinery;

[0130] (c) When the machine 10 moves across the ground 16, the milling drum 22 performs the milling operation;

[0131] (d) Determine the current x and y positions of the first end 28 of the milling drum 22 in a reference frame outside the construction machinery during the milling operation;

[0132] (e) Determine the current x, y position of the second end 30 of the milling drum 22 in a reference frame outside the construction machinery 10 during the milling operation;

[0133] (f) Using the controller 48, determine the desired milling depth of the first end 28 of the milling drum 22 at the current x, y position of the first end 28 of the milling drum 22 from the milling depth dataset;

[0134] (g) Using controller 48, determine the desired milling depth of the second end 30 of milling drum 22 at the current x, y position of the second end 30 of milling drum 22 from the milling depth dataset;

[0135] (h) Using controller 48, determine the desired lateral slope of the milling drum 22 at its current orientation relative to the current x and y positions of the first end 28 and the second end 30 of the milling drum from the design surface dataset; and

[0136] (i) Controlling the actual milling depth of the milling drum 22 by performing at least two steps selected from the following steps:

[0137] (i)(1) Control the actual milling depth of the first end 28 of the milling drum to correspond to the desired milling depth of the first end 28 at the current x, y position of the first end;

[0138] (i)(2) Control the actual milling depth of the second end 30 of the milling drum to correspond to the desired milling depth of the second end 30 at the current x, y position of the second end; and

[0139] (i)(3) Control the actual lateral slope of the milling drum 22 to correspond to the desired lateral slope of the milling drum 22 at the current x, y position of the first end 28 and the second end 30 of the milling drum.

[0140] The method may further include determining, during the milling operation, the current x, y position of at least one intermediate point on the milling drum 22, between the first and second ends of the milling drum, in a reference frame outside the construction machinery 10. This intermediate point can be determined... Figures 6-9 Above point 88. The slope control system 72 then uses any of several combinations of available input sensors to maintain the selected milling depth, typically two sensors selected from the left side plate sensor 50, the right side plate sensor 52, and the gravity-based lateral slope sensor 54.

[0141] In the above method, step (h) may further include determining, from the design surface dataset, the desired lateral slope of the milling drum 22 at the current x, y position of the first end 28 and the second end 30 of the milling drum 22 at the current x, y position of the milling drum 22 based on the design elevation of the design surface 82 at at least one intermediate point 88 and the design elevation of the design surface at the current x, y position of one of the first and second ends 30, such as... Figure 9 As shown schematically in the diagram.

[0142] Alternatively, in the above method, step (h) may include:

[0143] From the design surface dataset, it is determined that a crown 90 exists between the current x and y positions at the first and second ends of design surface 82; and

[0144] The desired lateral slope at the current x, y positions of the milling drum at the first and second ends of the milling drum is determined as the slope from the crown 90 through the design elevation corresponding to the x, y position of the one furthest from the crown 90 among the first end 28 and the second end 30, such as... Figure 9 As shown schematically in the diagram.

[0145] As an alternative to the above method, step (h) may include: determining, from a design surface dataset, the desired lateral slope of the milling drum 22 at its current position, based on multiple design elevations of the design surface, the design surface being a line extending through and beyond the design elevations of the design surface at the current x, y positions of the first end 28 and the second end 30 of the milling drum 22, as per the above. Figure 12 As schematically shown and described. The method may also include detecting discontinuities in the design elevation of the design surface along the line but laterally located beyond the length of the milling drum 22, such as the shoulder of the design surface.

[0146] The above method may also include preparing a milling depth dataset prior to step (a) by comparing the design surface dataset with a measurement dataset, which includes the actual x, y, and z coordinates of the existing ground 16 to be milled to produce the design surface 82.

[0147] In the above method, the measurement dataset is preferably not provided to the controller 48.

[0148] In the above method, steps (d) and (e) can be performed using a global navigation satellite system.

[0149] In the above method, the milling operation in step (c) can be as follows: Figure 3 The first milling operation shown in the figure has not yet milled the ground 16 adjacent to the first end 28 and the second end 30 of the milling drum 22 into the designed surface 82.

[0150] The above method may also include performing a second milling operation 2, such as Figure 4 and Figure 5 As shown in the diagram. The second milling operation 2 may include the following steps:

[0151] The milling depth of the second end 30 of the milling drum 22 adjacent to the milling belt 1 is controlled to match the existing elevation of the milling belt 1; and

[0152] During the second milling operation 2, use the above reference. Figures 6-9 The technique described above determines the desired lateral slope of the milling drum 22 at its current position from a design surface dataset.

[0153] Set the current x and y positions corresponding to the first end 28 and the second end 30 of the milling drum 22; and

[0154] During the second milling operation 2, the actual lateral slope of the milling drum 22 is controlled to correspond to the desired lateral slope of the milling drum at its current position.

[0155] Differences in paving using asphalt pavers:

[0156] Now refer to the attached diagram, and especially to... Figure 13 The diagram shows construction machinery in the form of an asphalt paver, generally identified by the numeral 110. Machinery 110 includes a machine frame 112. Multiple ground engagement units 114, shown in track form, support machinery 110 from the ground. Wheeled ground engagement units may also be used.

[0157] Viewed along the working direction A, a reservoir 116 for holding the material to be laid is arranged in the front area of ​​the mechanical frame 112. Located at the rear of the road paver 110 is a screed 118 for laying the material. The screed 118 can be described as an implement 118 of the paver 110. The driver's platform 120 is arranged between the reservoir 116 and the screed 118.

[0158] The screed 118 can be configured as a board that floats on the material to be laid. For this purpose, the screed 118 is connected to the mechanical frame 112 via pivot arms 122, and the screed 118 can be moved up and down relative to the mechanical frame 112 by pivoting the pivot arms 122 relative to the mechanical frame 112. Pivot actuators 124 can be connected between the mechanical frame 112 and each pivot arm 122 to control this pivoting movement. Specifically, the desired paving depth or thickness can be achieved by adjusting the set angle of the screed 118, which is determined by the height of the screed traction point. To adjust the screed traction point, the actuator 124 is disposed on the side of the mechanical frame 112. Using the actuator 124, not only the set angle of the screed 118 can be set, but also the inclination or lateral slope of the screed 118 can be set laterally to the direction of trimming A.

[0159] The paver 110 may carry at least one position data determining component 144 and 146, operable to determine position data thereby defining the current position of the left and right ends of the screed 118 in a reference frame external to the construction machinery. In embodiments of the paver, the position data determining component may be located on an end of the screed 118 or on a pivot arm 122 that moves with the screed 118. Note that in the context of a paver, this is preferred compared to a milling machine 10 where the position data determining component is located on the machine frame. This is because in the paver 110, the work implement moves vertically relative to the machine frame, while in the milling machine 10, the work implement can be vertically fixed relative to the machine frame. In the case of the paver, placing the position data determining component on or near the work implement provides a more direct measurement of the position of the work implement. However, it should be noted that the position data determination component can also be placed on the mechanical frame, even when using construction machinery such as asphalt pavers and the work implement is movable relative to the mechanical frame. In this case, sensors can be used to detect the relative movement, and then the controller can determine the position of the work implement relative to the mechanical frame.

[0160] Figures 14-17 With similar Figures 2-5 The method illustrates how the asphalt paver 110 performs its operation, in this case, the paving operation. Figure 14 This is a right-hand schematic diagram showing a paver 110 laying an asphalt paving layer 150 on a ground surface 16 to form a final paved surface 152. The paved surface 152 can be a design surface planned for the project. In this case, the ground surface 16 can be a pre-milled surface. The asphalt paving layer 150 can have a thickness 154, which can be referred to as the paving depth or working depth 154.

[0161] The paving depth 154 is determined by the height of the paving screed 118 above the ground, which can be detected, for example, by an ultrasonic sensor (such as 156) mounted on the screed 118 or on a structure connected to the screed (such as a pivot arm 122). Figure 15 As illustrated in the diagram, the screed 118 may also carry a gravity-based lateral slope sensor 158, which detects the actual lateral slope of the screed 118 from end to end.

[0162] The actual paving depth signal and actual lateral slope signal from sensors 156 and 158 can be received by a controller (e.g., controller 48) located on the paver 110. Controller 48 can then generate control signals sent to actuator 124 to raise or lower the ends of the pivot arm 122 and screed 118 as needed, in order to control the paving depth 154 according to the paving depth dataset and the design surface dataset, as described above. Figures 14-17 In the diagram, the design surface of the final paving surface, as defined by the design surface dataset, is represented by dashed line 182.

[0163] Figure 15 A rear view of a paver 110 is schematically shown creating a first working strip 180, in which case the first working strip 180 is a first paving strip 180. Figure 16 A schematic rear view of paver 110 is shown, with paver 110 creating a second working strip 181 adjacent to the first working strip 180. In this case, a right-end depth sensor 156 is used to match the right-side paving depth of the second working strip 181 with the paving depth of the adjacent first working strip 180. The lateral slope sensor 158 is then used to control the lateral slope of the second working strip 181 to be equal to the desired lateral slope at the x, y positions of the screed 118 (as determined from the design surface dataset).

[0164] Figure 18 An example is shown where the design surface 182 of the asphalt paving layer 150 includes a discontinuity, such as a crown 190. The controller 48 can detect the presence of the discontinuity 190 in the same manner as described above for a milling machine, by checking the design elevation of the design surface along a line extending through the end of the screed 118.

[0165] Verify the accuracy of the digital model:

[0166] As mentioned above, one problem with using automated systems to control construction machinery is the error in the digital model used to guide the automated operation of the machinery. For the digital model to accurately guide the automated operation of the construction machinery, the current ground surface being operated by the machinery needs to be identical to the actual ground surface described by the "actual ground dataset" determined in the initial measurements. This is true regardless of the type of digital model used, as other datasets such as the "operation depth dataset" and the "design surface dataset" are partially derived from the "actual ground dataset".

[0167] The description of the actual ground in the "actual ground dataset" determined in the initial measurements may contain errors compared to the actual ground encountered by construction machinery when it operates on the ground. These errors can arise in several ways, including:

[0168] 1. Incorrect measurements performed during the initial measurement phase;

[0169] 2. Modifications made to the ground after the initial measurements;

[0170] 3. Debris, such as dirt or milling material, that accumulates on the ground after the initial measurement;

[0171] 4. Incorrect sensor placement, for example, the sensor operating on the wrong surface; and

[0172] 5. The sensor used when the task was completed malfunctioned.

[0173] This disclosure provides an automated system in which a controller can view data from various sensors present on construction machinery and assess whether the data conforms to the expected data when the current ground conforms to the initial measurement constraints. If the current ground is confirmed to conform to the initial measurement constraints, construction work can proceed with confidence. If a potential error is detected, corrective actions can be taken.

[0174] The sensor used to confirm that the current ground conforms to the ground defined by the initial measurement is referred to herein as a "distance sensor". The distance sensor is a sensor configured to detect the distance between the mechanical frame 12 and the ground 16. The distance sensor does not actually need to provide a quantitative measurement of the actual distance between a point on the mechanical frame and the ground, but rather, taking into account the known geometry of the construction machinery and the known position of the sensor relative to the mechanical frame 12, it only generates a signal representing this distance.

[0175] Figure 19 This is a schematic diagram of control system 56, as shown in the previous section. Figure 10 The description, which schematically shows that it can be similar to Figure 1 Various position sensors are used on the road milling machine 10.

[0176] An example of such a distance sensor is the side panel sensors 50 and 52 mentioned above.

[0177] Another example is the sensors commonly referred to as lead sensors 200 and 202, which are ground engagement distance sensors located in front of the milling drum 22 near the left and right ends of the milling drum.

[0178] Another example is the outrigger extension sensor 204, which can be incorporated into the rising column 17 and provides a signal indicating the distance between the mechanical frame 12 and the ground 16 at each rising column. These outrigger extension sensors can be integrated into a hydraulic smart cylinder inside each rising column. Figure 19 As illustrated in the diagram, there can be four such outrigger extension sensors 204, with one such outrigger extension sensor 204 in each lifting column 17.

[0179] Another example of a suitable distance sensor is a scraper extension sensor 206, which can detect the position of the height-adjustable scraper 29 relative to the mechanical frame 12. There can be two such scraper extension sensors 206, one near each end of the scraper 29. The scraper extension sensor 206 can also be integrated into a hydraulic smart cylinder used to control the vertical position of the scraper 29 relative to the mechanical frame 12.

[0180] Another example of a suitable distance sensor could be a non-contact sensor. Similar to... Figures 14-16 As shown on the paver 110, the ultrasonic sensor 156 can also be used with a milling machine. Furthermore, it can be used with devices such as... Figure 20 The diagram illustrates a non-contact scanning technique using a scanning sensor 208. This scanning sensor 208 can be described in relation to U.S. Patent Publication No. 2024 / 0084529. Figure 17 The manner in which it is constructed is further described, and its details are incorporated herein by reference.

[0181] In addition to using the distance sensors described above, the techniques disclosed herein utilize data from one or more tilt sensors that can detect the orientation of the mechanical frame relative to a reference plane defined within a digital model in a reference frame outside the construction machinery 10. Such tilt sensors may include a gravity-based longitudinal tilt sensor 210 and a previously described gravity-based lateral tilt sensor 54. The longitudinal tilt sensor 210 detects the tilt relative to gravity along a length between the front and rear portions of the mechanical frame. The lateral tilt sensor 54 detects the tilt relative to gravity over the entire width between the left and right sides of the mechanical frame 12.

[0182] Another example of a suitable tilt sensor is a track angle sensor 213, which can detect the angle of one of the ground-engaging tracks 14 relative to the lifting column 17 to which it is attached. Such tracks 14 are typically pivotally mounted to the lower end of their respective lifting columns 17, such that the track pivots about an axis perpendicular to the length of the lifting column 17.

[0183] The technology disclosed herein is based on the principle that once the position of the construction machinery 10 within a reference frame outside the construction machinery (according to x and y coordinates) is known, various extended sensors will detect a predictable distance between the machinery frame 12 and the ground 16 if the elevation profile of the ground on which the construction machinery 10 sits is the same as the expected profile based on initial ground measurements. More specifically, any given pair of sensors selected from the available distance sensors will have a predictable relative orientation relative to each other and relative to a reference plane 214 defined in the reference system outside the construction machinery 10.

[0184] The basic steps of this technology include:

[0185] A digital model defined in a reference frame outside the construction machinery 10 is provided to the controller 48. This digital model is configured to guide the construction machinery to create the design surface 82 when the construction machinery is working on the ground 16.

[0186] The controller 48 determines the current relative orientation of the first and second sensors of at least one sensor pair among a plurality of distance sensors relative to each other and relative to a reference plane 214 defined within the digital model;

[0187] The controller 48 uses at least part of a digital model to determine the expected relative orientation of the first and second sensors of at least one sensor pair relative to each other and relative to the reference plane 214; and

[0188] The controller 48 compares the current relative orientation of at least one sensor pair with the expected relative orientation.

[0189] To confirm whether the current relative orientation matches the expected relative orientation.

[0190] Determine the current relative orientation:

[0191] The relative orientation of the sensor pair can only be deduced if a known reference surface 214 exists. This reference surface 214 can be defined solely for this purpose, and a physical representation of the reference surface is not required. A suitable choice for the reference surface 214 is a horizontal plane (relative to gravity), since this horizontal plane can be directly referenced by the aforementioned tilt sensors, and is thus determined by the distance measured by the distance sensors relative to the mechanical frame 12, and the orientation of the mechanical frame 12 relative to the reference plane is determined by the tilt sensors 210 and 54.

[0192] exist Figures 21A-21C An example of this process is illustrated schematically. For example... Figure 21A As seen, the construction machinery 10 includes a mechanical frame 12 and four ground-engaging tracks 14, which support the mechanical frame 12 via extendable lifting columns 17. Each lifting column 17 includes one of the outrigger extension sensors 204. A longitudinal inclination sensor 210 and a lateral inclination sensor 54 are mounted on the mechanical frame 12. A reference plane is designated 214, and in this case, is a horizontal plane perpendicular to the direction of gravity, and includes the contact point of the lowermost track 14, as measured along the longitudinal axis of its lifting column 17. In the example shown, the lowermost track is the left rear track 14LR.

[0193] Using a horizontal reference plane allows the inclination sensors 210 and 54 to determine the orientation of the mechanical frame 12 relative to the reference plane 214.

[0194] In this example, the pair of distance sensors would include a leg sensor 204 associated with the right front track 14RF and a leg sensor 204 associated with the left rear track 14LR.

[0195] like Figure 21BAs seen, the outrigger sensors 204 associated with the right front track 14RF and the left rear track 14LR measure extension distances 216 and 218, respectively. Then, based on the measurements from the slope sensors 210 and 54 and the known dimensions of the mechanical frame 12, the distance 220 of the mechanical frame 12 along the axis of the right front lifting column 17 from the horizontal reference plane 214 can be calculated. Finally, by subtracting the measured distance 216 of the right front track 14RF from the calculated distance 220 from the horizontal reference plane 214, the elevation difference 222 between the right front track 14RF and the left rear track 14LR from the horizontal reference plane 214 is determined. This difference 222 is the current relative orientation 222, relative to each other and relative to the reference plane 214 of the outrigger sensors 204 of the right front track 14RF and the left rear track 14LR. This can also be referred to as the “true vertical distance” 222 of the first and second sensors of the selected sensor pair relative to each other and relative to the reference plane defined within the digital model. It will be recognized that, regardless of the elevation of the chosen horizontal reference plane 214, the distance 222 defining the current relative orientation between the two distance sensors in question will be the same.

[0196] Similarly, the current relative orientation of any other pair of distance sensors can be determined. Figure 21C This illustrates the determination of the current relative orientation of a distance sensor pair, including outrigger sensor 204 associated with the right front track 14RF and outrigger sensor 204 associated with the right rear track 14RR. (As shown) Figure 21CAs seen, the outrigger sensors 204 associated with the right front track 14RF and the right rear track 14RR measure extension distances 216 and 226, respectively. Then, based on the measurements from the slope sensors 210 and 54 and the known dimensions of the mechanical frame 12, the distance 220 of the mechanical frame 12 along the axis of the right front lifting column 17 from the horizontal reference plane 214 can be calculated, and the distance 228 of the mechanical frame 12 along the axis of the right rear lifting column 17 from the horizontal reference plane 214 can also be calculated. The vertical distance 222 of the right front track 14RF above the horizontal reference plane 214 is determined by subtracting the measured distance 216 of the right front track 14RF from the calculated distance 220 to the horizontal reference plane 214. Furthermore, the vertical distance 230 of the right rear track 14RR above the horizontal reference plane 214 is determined by subtracting the measured distance 226 of the right rear track 14RR from the calculated distance 228 to the horizontal reference plane. The current relative orientation of the sensors associated with the right front track 14RF and the right rear track 14RR relative to each other and relative to the reference plane 214 is the difference 232 between distances 222 and 230. This can also be referred to as the “true vertical distance” 232 of the first and second sensors of the selected sensor pair relative to each other and relative to the reference plane defined within the digital model. It will be appreciated that the distance 232 defining the current relative orientation between the two distance sensors in question will be the same regardless of the elevation of the selected horizontal reference plane 214. This distance 232 represents the elevation difference relative to the reference plane 214 of the current ground, which is immediately below the centerline of the right front riser 17 associated with track 14RF and immediately below the centerline of the right rear riser 17 associated with track 14RR. If the current ground conforms to the expected ground, then distance 232 will be equal to the expected difference between the current ground elevation and the reference plane 214, which is immediately below the centerline of the right front lifting column 17 associated with track 14RF and immediately below the centerline of the right rear lifting column 17 associated with track 14RR.

[0197] It will be appreciated that the choice of reference plane 214 can be varied. Importantly, the orientation of the mechanical frame 12 relative to reference plane 214 is known, and the distance of at least one point on the mechanical frame relative to the reference plane is measurable. If a horizontal reference plane is chosen, the orientation of the mechanical frame 12 relative to the reference plane can be determined using gravity-based slope sensors 210 and 54. Figures 21A-21C As shown, the elevation of the lowest extended track 14 can be conveniently selected as the elevation of the reference plane 214, but any elevation of track 14 can also be selected as the elevation of the reference plane, which may only result in some distances being negative.

[0198] However, other types of reference planes can be defined. For example, a laser plane device can be used to define a reference plane within an external reference system, and then sensors used to detect the position and orientation of various points on the mechanical frame relative to the laser plane can be used to determine the orientation of the mechanical frame and the distance of the track from the reference plane.

[0199] The above technique can be described as a distance measurement method, wherein the controller 56 determines the current relative orientation by including the difference 232 between the current distance 222 between the first sensor 14RF and the reference plane 214 detected by the first sensor 14RF of at least one sensor pair and the current distance 230 between the second sensor 14RR and the reference plane 214 detected by the second sensor 14RR of at least one sensor pair. It will be understood that using the tracks 14RF and 14RR as references for "sensors" refers to the tracks 14, the lifting column 17, and the outrigger sensors 204, which together serve as distance sensors to detect the distances 216, 226 from the mechanical frame 12 to the ground, and thus determine the distances 222 and 230 from the respective tracks to the reference plane 214 by subtracting the aforementioned distances from the calculated distances 220, 228 to the reference plane.

[0200] The current relative orientation of the first and second sensors of at least one sensor pair of multiple distance sensors, relative to each other and relative to a reference plane defined within the digital model, can also be represented by “true angles” relative to each other and relative to the reference plane. This is in Figure 22 As shown in the diagram. Taking into account the true vertical distance 222 discussed above and the known horizontal distance between the sensors in question, the "true angle" 224 can be calculated. In this angle measurement method, determining the current relative orientation using the controller 56 includes determining the current angle 224 of the line between the ground contact point of the first sensor and the ground contact point of the second sensor of at least one sensor pair relative to the reference plane 214.

[0201] Determine the expected relative orientation:

[0202] The expected relative orientation between the two distance sensors in any selected distance sensor pair is determined from a digital model. This can be achieved by first determining the current position of a reference point on the construction machinery 10 in a reference frame outside the construction machinery using position data received by components 44, 46 to define the position data. For example, the position of the construction machinery can be determined using a GPS sensor. Based on this position data, the controller 56 can determine the current x, y position of each distance sensor being compared in a reference frame outside the construction machinery. Then, based on the selected digital model, the controller can calculate the expected difference between the vertical distances measured by the two distance sensors relative to each other and relative to the reference plane 214.

[0203] The digital model used can be any of the digital models described above or other models. The digital model can be an operational depth model, as described above, including an operational depth dataset and a design surface dataset. The digital model can also be an operational height model, as described above, including an actual ground dataset and a design surface dataset. Alternatively, the digital model can include both an actual ground dataset and an operational depth dataset.

[0204] The expected relative orientation can then be compared with the current relative orientation. If the current relative orientation for the selected sensor pair is equal to the expected relative orientation for that sensor pair, it is confirmed that the current ground where the machine is located is consistent with the initially measured ground.

[0205] If the current relative orientation of the selected sensor pair is not equal to the expected relative orientation for that sensor pair, it indicates that the current ground is inconsistent with the initially measured ground, or that there is a defect in one of the distance sensors. If only one pair of sensors is compared, all that is known is either ground inconsistency or a faulty sensor; we do not know which is the case. In this situation, controller 56 can provide a corrective action in response to the lack of consistency. This corrective action can be in the form of visual or audible markings that are observable by the operator at control panel 38. However, if multiple sensor pairs are examined, the system can provide further information and, in some cases, compensate for potential problems.

[0206] Preferably, this comparison is performed on multiple selected sensor pairs of available distance sensors. The more comparisons that are successfully performed confirming that the current relative orientation for a selected sensor pair is equal to the expected relative orientation for that sensor pair, the higher the confidence level that the current ground on which the machine rests conforms to the initially measured ground.

[0207] For example, suppose a plausibility check is performed on the following sensor pair:

[0208] 1) Left side panel sensor 50 + right side panel sensor 52;

[0209] 2) Left side plate sensor 50 + scraper sensor 206;

[0210] 3) Right side plate sensor 52 + scraper sensor 206.

[0211] If it is detected that pairs 1) and 3) are incorrect (the current relative orientation of the selected sensor pair is not equal to the expected relative orientation), and pair 2) is considered a valid sensor pair (the current relative orientation of the selected sensor pair is equal to the expected relative orientation), then the reading of sensor 52 on the right-hand sensor board is most likely the source of the error.

[0212] The more sensor pairs checked, the more reliable the detection of error sources. In the example above, if the additional left side plate sensor 50 and right side plate sensor 52 are checked relative to the track extension sensor 204 in the lifting column 17 and / or relative to the lead sensors 200, 202 in front of the milling drum 22, and only the combination involving the right side plate sensor 52 is detected to be incorrect, it becomes increasingly apparent that the right side plate sensor 52 is causing the problem.

[0213] The controller 48 can also provide corrective actions in the form of automatic responses executed by the controller 48. The controller 48 can initiate an operation shutdown procedure. The controller 48 can update the digital model and continue the operation. If the controller 48 determines that the inconsistency between the current relative orientation and the expected relative orientation of any sensor pair is due to a sensor failure of the distance sensor used to control the working depth of the work implement 22, the controller 48 can automatically switch the control of the working depth from the faulty sensor to a different sensor.

[0214] Confirmation that the current relative orientation of the selected sensor pair is equal to the expected relative orientation can be performed at various stages of the earthmoving operation. For example, a “start-up confirmation” can be performed by comparing the current relative orientation of the selected sensor pair with the expected relative orientation before starting work on the ground 16 with the work implement 22 to determine whether the current relative orientation of at least one sensor pair is consistent with coordinate data describing previously measured ground 16 in a reference frame outside the construction machinery 10.

[0215] Verification can also be performed during operation 16 on the ground using work implement 22 to determine whether the current relative orientation of at least one sensor pair is consistent with coordinate data describing the ground to be modified in a reference frame outside the construction machinery 10. "The ground to be modified" could, for example, be the milled surface 80 behind the milling machine 10, such as... Figure 2 As shown in the diagram. "Expected modified ground" will be defined in the digital model as an updated digital model of the original measured ground 16 to reflect the expected changes made by the work equipment 22. Reasonableness checks during operation can be used to: 1) detect obstacles; 2) detect faulty sensors; and / or 3) automatically switch sensors.

[0216] Identify faulty sensors:

[0217] As described above, comparing multiple selected sensor pairs can provide further useful information, such as helping to identify faulty sensors. For example, if a comparison indicates a lack of consistency between the current relative orientation and the expected relative orientation, this lack of consistency could be due to a faulty sensor reading or it could be due to an actual lack of consistency between the current ground and the initially measured ground.

[0218] Sensor malfunctions can be determined by observing sensor readings over time. If a sensor consistently involves an inconsistent current relative orientation between the sensor pairs over a period of time, this is an indication that the sensor may be malfunctioning. On the other hand, if the sensor appears to return to normal after a short period of time, this indicates that the sensor actually detected some unexpected obstacle on the ground. Furthermore, if a rear sensor (e.g., the right rear track) replicates the same obvious "error" as its leading sensor (e.g., the right front track), this indicates that both sensors actually detected the same obstacle on the ground.

[0219] If a defective sensor is detected, the machine operator can be notified so that corrective action can be taken.

[0220] Furthermore, if a comparison determines that the inconsistency between the current relative orientation and the expected relative orientation of any sensor pair is due to a sensor malfunction of the distance sensor used to control the working depth of the work implement 22, the controller 48 can automatically switch the control of the working depth from the faulty sensor to a different sensor.

[0221] On the other hand, if multiple comparisons show that the current ground level is inconsistent with the initially measured ground level, the differences in ground elevation can be recorded and the digital model can be updated.

[0222] If all the checked sensor pairs are deemed to be of reasonable cause, then no mechanical response is necessary.

[0223] If a sensor is identified as causing an error in the sensor pair and it is not currently used for milling depth control, the controller 48 can automatically send an alarm to the operator indicating that the sensor is currently unavailable.

[0224] If a sensor can be identified as the cause of the faulty sensor pair, and it is currently used for milling depth control, the controller 48 can automatically: 1) switch to another sensor if another sensor is present and available; 2) warn the operator; and / or 3) stop the machine operation.

[0225] If a sensor can be identified as the cause of any erroneous sensor pair, and if that sensor can be replaced by a different sensor, then there is no need to identify the potential problem. The problem is mitigated by disabling the sensor used for machine control, regardless of whether the digital model is correct or the sensor is faulty. Once the erroneous sensor pair is no longer detected, the controller 56 can switch back to the originally used sensor for work depth control.

[0226] If a sensor only temporarily causes an erroneous sensor pair, this can be used for obstacle detection. For example, an erroneous sensor might have engaged with a pile of dirt on the ground. After passing the dirt pile, there should no longer be any erroneous sensor pairs, and the system can switch back to the originally used sensor. The location of the "obstacle" can then be stored in the memory 60 of the controller 48.

[0227] If a sensor consistently causes erroneous sensor pairs, it can warn the operator of the potential presence of a faulty sensor.

[0228] If the system cannot definitively determine the source of the erroneous sensor pair, or if multiple sensors are causing erroneous readings, the controller 48 can warn the operator.

[0229] Alternative reference systems:

[0230] As previously mentioned, other reference systems besides satellite-based systems can be used. In the above embodiments, at least one position data determination component includes at least two position data determination components 44 and 46, which are in the form of Global Navigation Satellite System sensors, such as GPS sensors. In another embodiment, position data determination components 44 and 46 may be reflectors configured for use with a laser-based mechanical total station. If such a laser-based system is used, the reference plane 214 may, for example, be defined as a plane swept by a rotating laser source. In such a system, the reference plane does not need to be a horizontal plane.

[0231] Confirmation of X and Y orientation:

[0232] Another optional use of the system disclosed herein is to help determine the x, y orientation and / or orientation of construction machinery in a reference frame outside the construction machinery.

[0233] As will be understood by those skilled in the art, GPS sensor systems sometimes encounter operational difficulties, and GPS sensor signals may be temporarily lost or become unreliable. For example, GPS signals may be blocked by obstacles such as buildings, mountains, or other geological structures, or the GPS sensor may malfunction. In such cases, after the loss of GPS signals, various backup techniques are used to estimate the current x and y positions of the construction machinery to allow the machinery to continue operating until preferred GPS guidance can be re-established. One such technique is dead reckoning, which uses the last known x and y positions plus velocity and direction information to estimate the current x and y positions.

[0234] This system provides another technique for determining the current x, y position. If we assume that the current ground encountered by the construction machinery is the same as the previously measured actual ground, and as described in the actual ground dataset, then for all possible x, y orientations in the digital model, the current relative orientations of the various sensor pairs described above can be compared with the expected relative orientations to determine one or more possible x, y orientations of the construction machinery from which the current relative orientation of the sensors can be obtained. The more sensor pairs available for comparison, the more likely it is to determine the individual possible x, y orientation and orientation of the construction machinery. If multiple possible positions are identified, the data can be prioritized to determine the most probable current x, y orientation. For example, using elapsed time and forward velocity data from the last known x, y position of the construction machinery, the most probable current x, y position can be selected from the possible positions providing observed current relative orientation data.

[0235] Therefore, it can be seen that the apparatus and methods of the embodiments disclosed herein readily achieve the stated objects and advantages, as well as those inherent therein. While certain preferred embodiments have been shown and described for the purposes of this disclosure, many changes to the arrangement and construction of components and steps can be made by those skilled in the art, and these changes are included within the scope and spirit of the invention as defined by the appended claims.

Claims

1. A method of operating a construction machine, the construction machine comprising a machine frame, a work implement supported by the machine frame, a controller, and a plurality of distance sensors supported directly or indirectly from the machine frame, each respective distance sensor configured to detect a distance between the machine frame and the ground, the method comprising: providing to the controller a digital model defined within a frame of reference external to the construction machine, the digital model configured to guide the construction machine as the construction machine works on the ground to create a design surface; determining, with the controller, a current relative orientation of a first sensor and a second sensor of at least one pair of sensors of the plurality of distance sensors relative to one another and relative to a reference plane defined within the digital model; determining, with the controller, an expected relative orientation of the first sensor and the second sensor of the at least one pair of sensors relative to one another and relative to the reference plane based at least in part on the digital model; and comparing, with the controller, the expected relative orientation to the current relative orientation of the at least one pair of sensors to confirm whether the current relative orientation conforms to the expected relative orientation.

2. The method of claim 1, wherein: the construction machine further comprises at least one position data determining component operable to determine position data to define a current position of a reference point on the construction machine in a frame of reference external to the construction machine; and the method further comprises: receiving, with the controller, the position data; and determining, with the controller, a current x, y position of each distance sensor in the frame of reference external to the construction machine.

3. The method of claim 1, wherein: the digital model comprises a work depth data set comprising x and y coordinate data in the frame of reference external to the construction machine and comprising desired work depth data corresponding to the x and y coordinate data; and the digital model further comprises a design surface data set defining a design surface to be created, the design surface data set comprising x, y, and z coordinate data of the design surface in the frame of reference external to the construction machine.

4. The method of claim 1, wherein: the digital model comprises an actual ground data set comprising x, y, and z coordinate data describing an actual ground previously measured in the frame of reference external to the construction machine; and the digital model further comprises a design surface data set defining a design surface to be created, the design surface data set comprising x, y, and z coordinate data of the design surface in the frame of reference external to the construction machine.

5. The method of claim 1, wherein: the digital model comprises an actual ground data set comprising x, y, and z coordinate data describing an actual ground previously measured in time in the frame of reference external to the construction machine; and ​ ​ ​ ​ ​ The digital model also includes a job depth data set comprising x and y coordinate data in the frame of reference external to the construction machine, and comprising expected job depth data corresponding to the x and y coordinate data.

6. The method of claim 1 wherein: The reference plane within the digital model is a horizontal reference plane defined as a reference plane perpendicular to the direction of gravity in the frame of reference external to the construction machine.

7. The method of claim 6, wherein, Also included is: Detecting, with at least one slope sensor, a slope of the machine frame relative to the direction of gravity and thereby relative to the reference plane.

8. The method of claim 6, wherein, Also included is: Detecting, with a longitudinal slope sensor, a longitudinal slope of the machine frame relative to the direction of gravity; And Detecting, with a lateral slope sensor, a lateral slope of the machine frame relative to the direction of gravity, the lateral slope being perpendicular to the longitudinal slope.

9. The method of claim 1 wherein: The comparison is performed prior to commencing work on the ground with the work implement to determine whether the current relative orientation of the at least one sensor pair is consistent with the digital model.

10. The method of claim 1 wherein: The comparison is performed during work on the ground with the work implement to determine whether the current relative orientation of the at least one sensor pair is consistent with coordinate data describing an expected ground in the frame of reference external to the construction machine.

11. The method of claim 1 wherein: In determining the current relative orientation and the expected relative orientation of the at least one sensor pair, the at least one sensor pair comprises a plurality of sensor pairs.

12. The method of claim 11 wherein: The comparison includes determining whether the inconsistency of the current relative orientation with the expected relative orientation of any one sensor pair is due to a change in the ground subsequent to preparation of the digital model or due to a sensor malfunction.

13. The method of claim 12 wherein: The comparison includes identifying a malfunctioning sensor as a sensor present in a plurality of sensor pairs for which there is a lack of consistency in the current relative orientation with the expected relative orientation of the respective sensor pair over a period of time.

14. The method of claim 12, wherein, Also included is: If the comparison determines that the lack of consistency of the current relative orientation with the expected relative orientation of any one sensor pair is due to a change in the ground subsequent to preparation of the digital model, updating the digital model to reflect the change.

15. The method of claim 12, wherein Also included is: If the comparison determines that the lack of consistency of the current relative orientation with the expected relative orientation of any one sensor pair is due to a sensor malfunction of a distance sensor used to control a job depth of the work implement, automatically switching control of the job depth from the malfunctioning sensor to a different sensor.

16. The method of claim 1 wherein: Determining, with the controller, the current relative orientation includes determining a difference between a current distance between the first sensor of the at least one sensor pair and the reference plane detected by the first sensor and a current distance between the second sensor of the at least one sensor pair and the reference plane detected by the second sensor.

17. The method of claim 1, wherein: determining the current relative orientation includes determining a current angle of a line between a ground contact point of the first sensor and a ground contact point of the second sensor of the at least one pair of sensors relative to the reference plane.

18. A construction machine comprising: a machine frame; a work implement supported by the machine frame for working the ground as the machine moves across the ground during a work operation; a plurality of distance sensors supported directly or indirectly by the machine frame, each respective distance sensor configured to detect a distance between the machine frame and the ground; at least one slope sensor configured to detect a slope of the machine frame relative to a direction of gravity; at least one position data determining component operable to determine position data to define a current position of a reference point on the construction machine in a reference frame external to the construction machine; and a controller associated with a memory having stored therein a digital model defined within the reference frame external to the construction machine, the controller operable to receive the position data from the at least one position data determining component, wherein the controller is configured to: determine a current x, y position of each of the distance sensors in the reference frame external to the construction machine; determine a current relative orientation of a first sensor and a second sensor of at least one pair of sensors of the plurality of distance sensors relative to each other and relative to a reference plane defined within the digital model; determine an expected relative orientation of the first sensor and the second sensor of the at least one pair of sensors relative to each other and relative to the reference plane based at least in part on the digital model; compare the current relative orientation of the at least one pair of sensors to the expected relative orientation to confirm whether the current relative orientation conforms to the expected relative orientation; and provide a corrective action in response to a lack of conformity of the current relative orientation of either pair of sensors to the expected relative orientation.

19. The construction machine of claim 18, wherein: the digital model includes a work depth data set including x and y coordinate data in the reference frame external to the construction machine and including desired work depth data corresponding to the x and y coordinate data; and the digital terrain model further includes a design surface data set defining a design surface to be created, the design surface data set including x, y, and z coordinate data of the design surface in the reference system external to the construction machine.

20. The construction machine of claim 18, wherein: the digital model includes an actual ground data set including x, y, and z coordinate data describing an actual ground previously measured in the reference system external to the construction machine; and the digital terrain model further includes a design surface data set defining a design surface to be created, the design surface data set including x, y, and z coordinate data of the design surface in the reference system external to the construction machine. ​ ​ ​ 21. The construction machine of claim 18, characterized by: the digital model including an actual ground data set including x, y, and z coordinate data describing actual ground previously measured in a reference system external to the construction machine; and the digital model further including a work depth data set including x and y coordinate data in the reference system external to the construction machine and including desired work depth data corresponding to the x and y coordinate data.

22. The construction machine of claim 18, characterized by: the reference plane within the digital model being a horizontal reference plane defined as a reference plane perpendicular to a direction of gravity in the reference system external to the construction machine.

23. The construction machine of claim 18, characterized by: the at least one slope sensor including a longitudinal slope sensor configured to detect a longitudinal slope of the machine frame relative to a direction of gravity and a lateral slope sensor configured to detect a lateral slope of the machine frame relative to the direction of gravity, the lateral slope being perpendicular to the longitudinal slope.

24. The construction machine of claim 18, wherein further comprising: a plurality of track ground engaging units supporting the machine frame from the ground; wherein the at least one slope sensor includes a track angle sensor configured to detect an angle of inclination of at least one of the track ground engaging units relative to the machine frame.

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