Remote operation system of work machine
The remote control system for industrial machinery automatically adjusts the work machine's coordinate system based on the remote controller's attitude, addressing inefficiencies in existing systems by ensuring seamless operation despite changes in relative angles, thus enhancing operational efficiency and intuitiveness.
Patent Information
- Application Number
- JP2024054896
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-03-28
- Publication Date
- 2025-10-10
Smart Images

Figure 2025152803000001_ABST
Abstract
Description
[Technical Field]
[0001] The present invention relates to a remote control system for remotely controlling a work unit of an industrial machine. [Background technology]
[0002] BACKGROUND ART Conventionally, in order to operate a work machine such as a mobile crane, an operating device provided on the machine body or a remote control connected to the machine body by wire or wirelessly has been used. Such remote control devices are equipped with an input device that corresponds to one of the actuators of the work equipment. Therefore, when, for example, moving a load suspended by a crane in parallel, the operator must combine multiple inputs to perform the desired operation.
[0003] Here, Patent Document 1 discloses a wireless controller that can move a hook in parallel by combining a plurality of operations. In such a wireless controller, multiple actuators work in conjunction with each other so that the hook moves in the direction in which the stick is tilted, with the front-to-rear direction of the vehicle corresponding to the Y axis of the input device.
[0004] The wireless controller disclosed in Patent Document 1 requires that the direction in which the operator is facing and the fore-and-aft direction of the vehicle be aligned in order to operate it smoothly. However, when using a remote controller, operators often perform work while changing their position relative to the vehicle, and since the reference direction for input operations is fixed, it is time-consuming for the operator to check the fore-and-aft direction of the vehicle before performing input operations.
[0005] Therefore, with the remote controller disclosed in Patent Document 2, it is possible to set an operation direction reference that serves as a reference for the direction of movement of the hook by operating the reference change operating tool 34 disclosed in Figure 5 of the same document. Note that it is disclosed that the reference change operating tool 34 is, for example, a rotation angle sensor or the like, and is a device that can be operated at will by the operator. [Prior art documents] [Patent documents]
[0006] [Patent Document 1] Japanese Patent Application Laid-Open No. 2010-228905 [Patent Document 2] Japanese Patent Application Publication No. 2019-108180 Summary of the Invention [Problem to be solved by the invention]
[0007] However, the reference change operating tool 34 disclosed in Patent Document 2 is a device that is operated at the discretion of the operator, and therefore, in order to operate the work equipment smoothly, the operator must operate it each time and set the operating direction reference.
[0008] Therefore, for example, when operating a crane while the worker is moving together with the suspended load, the worker must take the time to change the settings if the positional relationship with the suspended load changes, etc. Furthermore, after the suspended load has been moved to a desired location, the worker must also take the time to change the settings when moving the hook to a location where a new load is on the ground. Specifically, in a mobile crane in which a crane device is mounted on a truck, a case is envisaged in which a load loaded on the loading platform is moved to a location away from the mobile crane, and the hook is moved toward the loading platform to lift the load loaded on the loading platform.
[0009] In view of the above circumstances, an object of the present invention is to provide a remote control system for industrial machinery that allows work to be continued smoothly even if the relative angle between the industrial machinery and the remote controller changes. [Means for solving the problem]
[0010] A first invention is a remote operation system for a work machine, comprising an industrial machine having a work machine rotatable about a pivot axis along a vertical direction and a control unit for controlling the work machine, and a remote controller for operating the work machine, wherein a single operation input causes a plurality of actuators of the work machine to be operated in combination, thereby enabling linked operation to linearly move an operation reference part set at a predetermined position on the work machine, wherein a reference coordinate system based on the industrial machine, a work machine coordinate system based on the work machine and in which a predetermined initial attitude is set, and a remote controller coordinate system based on the remote controller and in which a rotational attitude relative to the remote controller is fixed are set, the work machine comprises a work machine attitude detection unit that detects its own attitude, the control unit comprises a receiving unit, a reference attitude setting unit, a compensation calculation unit and an operation control unit, the remote controller comprises an input unit, a remote controller attitude detection unit and a transmission unit, the input unit receives an operation direction of the operation reference part in the work machine coordinate system, and the control unit receives an operation direction of the operation reference part in the work machine coordinate system. the remote controller attitude detection unit detects the rotational attitude of the remote controller in the reference coordinate system; the transmission unit transmits the input value of the input unit and the detection value of the remote controller attitude detection unit; the receiving unit receives the information transmitted from the transmission unit; the reference attitude setting unit sets the detection value of the remote controller attitude detection unit as the reference attitude when the initial attitude of the work machine coordinate system in the reference coordinate system and the rotational attitude of the remote controller coordinate system in the reference coordinate system coincide; the compensation calculation unit performs calculation to rotate and compensate the work machine coordinate system from the initial attitude to a predetermined rotational attitude that corresponds to the rotational attitude of the remote controller coordinate system in the reference coordinate system, based on the detection value of the work machine attitude detection unit, the detection value of the remote controller attitude detection unit, and the reference attitude; and the operation control unit controls the movement direction and movement speed of the actuator based on the input value of the input unit and the calculation result of the compensation calculation unit.
[0011] A second invention is a remote control system for a work machine, characterized in that the predetermined rotational posture described in the first invention is a rotational posture obtained by rotating the work machine coordinate system from the initial posture around an axis along the vertical direction in the reference coordinate system by a predetermined angle that is set based on the rotation angle of the remote control coordinate system around an axis along the vertical direction in the reference coordinate system.
[0012] A third invention is a remote control system for a work machine, characterized in that the predetermined angle described in the second invention is equal to the rotation angle of the remote controller coordinate system around an axis along the vertical direction in the reference coordinate system.
[0013] A fourth invention is a remote control system for a work machine, characterized in that the predetermined rotational attitude described in the first invention is a rotational attitude obtained by rotating the work machine coordinate system three-dimensionally from the initial attitude by a predetermined angle set around each of the three rotational axes based on the rotation angles around the three rotational axes of the remote control coordinate system expressed by Euler angles in the reference coordinate system.
[0014] A fifth invention is a remote control system for a work machine, characterized in that the predetermined angles set for each of the three rotation axes described in the fourth invention are angles at which the rotational attitude of the remote control coordinate system coincides with the rotational attitude of the work machine coordinate system rotated three-dimensionally.
[0015] A sixth invention is a remote control system for a work machine, characterized in that the input unit described in any one of the first to fifth inventions has input axes oriented along two of the coordinate axes of the remote control coordinate system.
[0016] A seventh invention is a remote control system for a work machine, wherein the work machine according to any one of the first to fifth inventions comprises an extendable boom and a hook connected to a wire rope wound around a winch and hanging down from the tip of the boom, the operation reference unit is set at the tip of the boom, the work machine attitude detection unit comprises a wire length detection unit and a boom length detection unit, the control unit further comprises a hook position calculation unit that calculates the distance between the tip of the boom and the hook based on detection values of the wire length detection unit and the boom length detection unit, and the operation control unit operates the winch during the linked operation so as to maintain a constant distance between the tip of the boom and the hook based on the detection value of the boom length detection unit and the calculation result of the hook position calculation unit.
[0017] The eighth invention is a remote control system for a work machine, characterized in that the remote control attitude detection unit described in any one of the first to fifth inventions includes a three-axis acceleration sensor, a three-axis angular velocity sensor, and a three-axis geomagnetic sensor.
[0018] A ninth invention is a remote control system for a work machine, characterized in that the predetermined initial attitude of the work machine coordinate system described in any one of the first to fifth inventions is set to a rotational attitude when the work machine coordinate system itself is aligned with the rotational attitude of the reference coordinate system. [Effects of the Invention]
[0019] According to the present invention, it is possible to provide a remote control system and a remote controller for industrial machinery that allow work to be continued smoothly even if the relative angle between the industrial machinery and the remote controller changes. [Brief explanation of the drawings]
[0020] [Figure 1] 1 is a side view of a mobile crane according to a first embodiment of the present invention. FIG. [Figure 2]1A is a diagram showing the structure and remote control coordinate system of a remote control according to a first embodiment of the present invention, and FIG. 1B is a diagram showing assignment of input units. [Figure 3] 1 is a diagram illustrating a configuration of a crane apparatus according to a first embodiment of the present invention. FIG. [Figure 4] 1 is a diagram showing a configuration of a remote controller according to a first embodiment of the present invention; [Figure 5] 3A and 3B are diagrams illustrating settings of a reference coordinate system, an initial attitude of a remote controller coordinate system, and a reference attitude of a remote controller according to the first embodiment of the present invention. [Figure 6] 4 is a flowchart showing the operation of the remote controller and the control unit according to the first embodiment of the present invention. [Figure 7] 4 is a flowchart showing the operation of the remote controller and the control unit according to the first embodiment of the present invention. [Figure 8] 10A and 10B are diagrams illustrating the relationship between the input direction and the movement direction when a conventional linked movement is performed. [Figure 9] 3A and 3B are diagrams schematically showing the relationship between the input direction and the movement direction when performing a linked movement using the operation system according to the first embodiment of the present invention. [Figure 10] 5A and 5B are diagrams illustrating the calculation of the movement direction during the linked movement according to the first embodiment of the present invention. [Figure 11] 10A and 10B are diagrams illustrating the relationship between the input direction and the movement direction when a linked movement is performed using the operation system according to the second embodiment of the present invention. [Figure 12] 10A and 10B are diagrams illustrating the relationship between an input method and an operation method when performing a linked operation using an operation system according to a second embodiment of the present invention. [Figure 13] 10 is a diagram illustrating a schematic diagram of calculation of a movement direction during a linked movement according to the second embodiment of the present invention. FIG. [Figure 14] 10A and 10B are diagrams illustrating the relationship between an input method and an operation method when performing a linked operation using an operation system according to a second embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION
[0021] First Embodiment The following describes an operating system for industrial machinery, with appropriate reference to the drawings. It should be noted that the drawings are schematic. Therefore, it should be noted that the relationships and ratios between thicknesses and planar dimensions may differ from those in reality, and that the relationships and ratios between dimensions may differ between drawings. Furthermore, the embodiments shown below are merely examples of devices and methods that embody the technical concept of the present invention, and the technical concept of the present invention is not limited to the following embodiments in terms of the materials, shapes, structures, arrangements, etc. of the components. In the following description, only the parts related to the present invention will be described in detail, and other parts will be only briefly described or will not be described at all.
[0022] In the following explanation and drawings, a mobile crane in which a vehicle-mounted crane device is mounted on a truck will be described as an example of an industrial machine equipped with a work implement. In the following explanation, unless otherwise specified, the crane device equipped on the mobile crane will be assumed to be in a stowed position in which the tip of the boom is tilted approximately horizontally toward the rear of the vehicle and its length is aligned with the fore-and-aft direction of the vehicle. Additionally, the direction in which the mobile crane moves forward (the direction in which it travels when the shift is selected in D range, etc.) may be referred to as "forward." Similarly, in the following explanations and drawings, the direction in which the mobile crane moves backward (the direction in which it travels when the shift is selected in R range) may be referred to as "rearward," and the left hand side of the operator of the mobile crane 1 when he is sitting in the driver's seat will be referred to as the "left side," and the right hand side of the operator when he is sitting in the driver's seat will be referred to as the "right side." Therefore, in the following explanations and drawings, expressions such as "vehicle front side," "vehicle rear side," "vehicle right side," and "vehicle left side" may be used in accordance with this definition. Also, the expression "vehicle width direction" may be used to indicate the vehicle left side and vehicle right side.
[0023] <Mobile crane structure> The structure of the mobile crane 1 will be described with reference to FIG. The mobile crane 1 is constructed by mounting a vehicle-mounted crane on a chassis frame CF of a truck. The vehicle-mounted crane has a base B attached to the bottom, which is fixed to the chassis frame CF, and a crane device 10, which is a working machine, attached to the top of the base B. The base B is equipped with outrigger devices OU that protrude outward in the vehicle width direction to ensure the stability of the mobile crane 1. Furthermore, a control valve C that distributes pressure oil supplied from a pump (not shown) to the actuators of the crane apparatus 10 is fixed to the upper part of the base B.
[0024] <Crane device structure> The structure of the crane apparatus 10 will be described with reference to FIGS. 1, the crane apparatus 10 includes, from the bottom, a slewing device 11, a column 12, a boom 13, a hook 18, and a control unit 50. The detailed configuration of the control unit 50 will be described later. The swivel device 11 is provided on the upper part of the base B and supports the base of the column 12 so that it can rotate around an axis along the vertical direction of the vehicle, and the upper end of the column 12 supports the base end of the boom 13 so that it can swing around an axis along the width direction of the vehicle.
[0025] As shown in Figure 3, the crane apparatus 10 is equipped with an actuator AC for swinging, raising and lowering the boom, extending and retracting the boom, and moving the hook up and down. Specifically, a swing motor 14 is provided on the swing device 11 for swinging, a winch 15 is provided on the top of the column 12 for moving the hook up and down, and one end of a derrick cylinder 16 is supported on the top of the swing device 11 for boom hoisting so as to be swingable about an axis along the vehicle width direction, and the other end is supported on the longitudinal center of the boom 13 so as to be swingable about an axis along the vehicle width direction. The boom 13 has a telescopic mechanism and includes a tele-cylinder 17 for extension and retraction inside.
[0026] As shown in Figure 1, a wire rope W is wound around the winch 15, and a hook 18 is connected to the end of the wire rope W. The wire rope W hangs down from the hook 18 via the tip of the boom 13. Furthermore, at the tip of the boom 13, above the hook 18, an operation reference portion 90, which will be described later, is set.
[0027] As shown in FIG. 3, the crane device 10 is equipped with a work machine attitude detection unit 20, which includes a boom angle detection unit 21, a boom length detection unit 22, a swing angle detection unit 23, and a wire length detection unit 24, in order to detect its own attitude, and transmits the detected values to the control unit 50. The boom angle detection unit 21 is provided on the top of the column 12 and detects the angle between the column 12 and the boom 13. The boom length detection unit 22 is provided inside the boom 13 and detects the length of the boom 13 . The swing angle detection unit 23 is provided in the swing device 11 and detects the swing angle of the column 12 and the boom 13 relative to the base B. The wire length detector 24 is provided on the winch 15 and detects the length of the wire rope W based on the rotation angle of the winch 15.
[0028] <Remote control device structure> The remote controller 30 will be described with reference to FIGS. 2(a), the remote controller 30 includes a grip portion 31 and a main body portion 32. Although not shown, a battery pack is inserted into the grip portion 31 as a power source.
[0029] As shown in FIG. 2(b), the main body 32 is provided with a display unit 33 that displays information such as the operation mode, and on the grip unit 31 side of the display unit 33 are provided an input unit IP, which includes a left stick 34, a right stick 35, and a setting switch 36. The left stick 34 and the right stick 35 are used to operate the crane apparatus 10 and the outrigger apparatus OU. A setting switch 36 is provided to switch the operation target between the crane apparatus 10 and the outrigger apparatus OU, and to switch between an interlocking operation mode and a normal operation mode, which will be described later.
[0030] In the following description, the side on which the display unit 33 is provided is defined as the front of the remote controller 30, the side on which the main body 32 is provided is defined as the top, and the side on which the grip is provided is defined as the bottom. In the following description, when expressions such as "top," "bottom," "left side," "right side," "front side," and "rear side" of the remote controller 30 are used, the definitions of each direction will be based on those definitions.
[0031] As shown in Figure 4, the left stick 34 and the right stick 35 are equipped with two-axis sensors that detect the magnitude and direction of tilt. The two-axis sensors consist of X-axis sensors 37L and 37R that detect left-right tilt and Y-axis sensors 38L and 38R that detect up-down tilt, and detect the direction and magnitude of stick tilt in the form of coordinate values on the X and Y axes. Note that a biasing force is applied to the left stick 34 and the right stick 35 when no external force is applied, so that the left stick 34 and the right stick 35 automatically return to their origin positions, where the input values of the two-axis sensors are 0 on both the X and Y axes.
[0032] As shown in FIG. 2(b), the operation assignment of the input unit IP during linked operation is such that the X axis is assigned to the left and right direction of the left stick 34, the Y axis is assigned to the up and down direction, and the Z axis is assigned to the left and right direction of the right stick 35, and the up and down operation of the hook 18 is assigned to the up and down direction. Specifically, the left stick 34 is set with the right side as +X, the left side as -X, the top as +Y, and the bottom as -Y, with the origin position as the center, and the right stick 35 is set with the right side as +Z, the left side as -Z, the top as winding up (hook up), and the bottom as winding down (hook down), with the origin position as the center.
[0033] As shown in FIG. 4, the remote controller 30 further includes a transmitter 39 and a remote controller attitude detector 40. The remote controller attitude detection unit 40 is equipped with a three-axis acceleration sensor 41, a three-axis angular velocity sensor 42, and a three-axis geomagnetic sensor 43 as sensors for detecting the rotational attitude of the remote controller 30, and detects the three-dimensional rotational attitude of the remote controller 30 based on the detection values of each sensor. The transmitter 39 wirelessly transmits the input value of the input unit IP and the detection value of the remote controller attitude detector 40 to the control unit 50.
[0034] <Control unit configuration> The configuration of the control unit 50 will be described with reference to FIG. The control unit 50 includes a receiving section 51 , a reference attitude setting section 52 , a compensation calculation section 53 , a motion control section 54 , and a hook position calculation section 55 . The receiving unit 51 receives information transmitted from the transmitting unit 39 of the remote controller 30 . In the reference attitude setting section 52, a detection value of the remote controller attitude detection section 40 at a time to be described later is set as the reference attitude. The compensation calculation unit 53 performs a calculation to rotationally compensate the rotational attitude of the work machine coordinate system C2 based on the detection value of the remote controller attitude detection unit 40 and the reference attitude. The operation control unit 54 controls the direction and speed of operation of the actuator AC based on the input values of the left stick 34 and the right stick 35 and the calculation results of the compensation calculation unit 53. The hook position calculation unit 55 calculates the distance between the boom 13 and the hook 18 based on the detection value of the work machine attitude detection unit 20.
[0035] <Coordinate system settings> The setting of the reference coordinate system C1, the work machine coordinate system C2, and the remote controller coordinate system C3 will be described with reference to FIG. 2(a) and FIG. In the following explanation, when indicating rotation angles around Euler angles, the rotation angle around the pitch axis will be represented as θ [°], the rotation angle around the roll axis as Φ [°], and the rotation angle around the yaw axis as Ψ [°], and these may be collectively expressed as (θ, Φ, Ψ). Furthermore, when viewed from the + side of each axis, the clockwise direction will be expressed as + rotation, and the counterclockwise direction will be expressed as - rotation.
[0036] (reference coordinate system) The reference coordinate system C1 shown in Figure 5 is a three-dimensional Cartesian coordinate system that is set with the mobile crane 1 as the reference in order to define the rotational attitude of other coordinate systems. Specifically, the X-axis (pitch axis) is set along the width direction of the mobile crane 1, the Y-axis (roll axis) is set along the fore-and-aft direction of the mobile crane 1, and the Z-axis (yaw axis) is set along the up-and-down direction of the mobile crane 1. The Z-axis is also set along the vertical direction. In the following description, the coordinate axes of the reference coordinate system C1 will be referred to as the Xs-axis, the Ys-axis, and the Zs-axis. The positive direction of the Xs-axis is the direction from the right side of the vehicle to the left side of the vehicle, the positive direction of the Ys-axis is the direction from the front side of the vehicle to the rear side of the vehicle, and the positive direction of the Zs-axis is the direction from the bottom side of the vehicle to the top side of the vehicle.
[0037] (Working machine coordinate system) The work machine coordinate system C2 shown in Figure 5 is a three-dimensional Cartesian coordinate system whose origin is set on the rotation axis of the crane apparatus 10 in order to determine the movement direction of the operation reference part 90 set at the tip of the boom 13. The rotational orientation of the work machine coordinate system C2 in the reference coordinate system C1 changes through a correction process described below, but a predetermined initial orientation is set as a reference for the rotational orientation. The initial orientation is set to a rotational orientation in which each coordinate axis of the work machine coordinate system C2 is aligned with each coordinate axis of the reference coordinate system C1. That is, the work machine coordinate system C2 in the initial posture is set so that the X axis is along the vehicle width direction of the mobile crane 1, the Y axis is along the vehicle fore-and-aft direction of the mobile crane 1, and the Z axis is along the vehicle up-and-down direction. In the following description, the coordinate axes of the work machine coordinate system C2 will be referred to as the Xc-axis, the Yc-axis, and the Zc-axis. When the work machine coordinate system C2 is in its initial posture, the direction from the right side of the vehicle to the left side of the vehicle will be the positive direction of the Xc-axis, the direction from the front side of the vehicle to the rear side of the vehicle will be the positive direction of the Yc-axis, and the direction from the bottom side of the vehicle to the top side of the vehicle will be the positive direction of the Zc-axis.
[0038] (remote control coordinate system) 2(a), the remote controller coordinate system C3 is a three-dimensional Cartesian coordinate system set with the remote controller 30 as the reference. Specifically, the X axis is set along the left-right direction of the remote controller 30, the Y axis is set along the up-down direction of the remote controller 30, and the Z axis is set along the front-rear direction of the remote controller 30. In the following explanation, the coordinate axes of the remote controller coordinate system C3 will be referred to as the XTx axis, the Y axis as the YTx axis, and the Z axis as the ZTx axis. The direction from the left to the right of the remote controller 30 is the positive direction of the XTx axis, the direction from the bottom to the top of the remote controller 30 is the positive direction of the Y axis, and the direction from the back to the front of the remote controller 30 is the positive direction of the Z axis.
[0039] <Remote control system operation> (Overview of operation) The flow of operations of the remote control system will be described mainly with reference to FIGS. As shown in FIG. 6, when the remote controller 30 is started up, pairing is first performed to establish communication between the remote controller 30 and the control unit 50 (SR01, SC01).
[0040] When pairing is complete, the remote controller coordinate system C3 and the work machine coordinate system C2 are initialized (SR02, SC02). Specifically, the work machine coordinate system C2 is reset to its initial attitude, and the reference attitude of the remote controller 30 is set. In this embodiment, the attitude of the remote controller 30 at the time of pairing completion is set as the reference attitude. Therefore, during pairing, as shown in FIG. 5, the remote controller 30 is held in a rotated attitude in which the remote controller coordinate system C3 and the work machine coordinate system C2 coincide. Note that the reference attitude can be set at any time by performing a predetermined operation on the remote controller 30. When the reference posture is being set, a screen indicating that the reference posture is being set is displayed on the display unit 33 of the remote controller 30 shown in FIG. 2(b), and once the setting is complete, a screen for crane operation is displayed.
[0041] The remote controller 30 shown in this embodiment is equipped with a triaxial geomagnetic sensor 53 as the remote controller attitude detection unit 40, and is capable of detecting not only the rotational attitude in the reference coordinate system C1 but also the rotational attitude based on the absolute orientation. Therefore, when the reference orientation is set, information about the rotational attitude of the reference orientation based on the absolute orientation is also stored. By storing the rotational attitude of the reference attitude based on the absolute orientation, it is possible to omit the procedure of initializing the remote controller coordinate system C3 and the work machine coordinate system C2 when the remote controller 30 is turned off without moving the mobile crane 1 and then started up again, such as when work using the crane apparatus 10 is temporarily suspended. In this embodiment, it is determined that a restart after a temporary suspension has occurred by turning on the power while pressing a specific switch.
[0042] Thereafter, when the setting switch 36 of the remote controller 30 is operated to select the linked operation mode (SR03: YES), the transmitter 39 transmits a linked operation mode signal to the control unit 50 (SR04). The control unit then receives the linked operation mode signal (SC03: YES) and transmits a switching permission signal (SC04), which is then received by the remote controller (SR05), thereby switching to the linked operation mode. If the interlocking operation mode is not selected (SR03: NO, SC03: NO), the system operates in the normal operation mode, which operates each actuator AC individually. The normal operation mode is a commonly used method of operating the working equipment of industrial machinery, and therefore a description thereof will be omitted.
[0043] As shown in Fig. 7, while the linked operation mode is set, the remote controller attitude detection unit 40 detects the rotational attitude and transmits it to the control unit 50 (SR11, SR12), while simultaneously transmitting input operations (SR13, SR14). The control unit 50 receives this information (SC11, SC12), and the compensation calculation unit 53 performs a calculation process to rotationally compensate the rotational attitude of the work machine coordinate system C2 to a predetermined rotational attitude, which will be described later, based on the rotational attitude of the remote controller 30. Thereafter, the operation control unit 54 calculates the operation direction and operation speed for each actuator AC (SC14, SC15), and outputs them as an operation command (SC16). Thereafter, the operation in the linked operation mode is repeated until the linked operation mode is switched to the normal operation mode (SR15: YES, SC17: NO).
[0044] Thereafter, when a switch operation from the interlocked operation mode to the normal operation mode is performed (SR15: NO, SC17: NO), first a switch signal is transmitted from the remote controller 30 (SR16). The control unit 50 receives the switch signal (SC17: YES) and transmits a switch permission signal (SC18). When the remote controller 30 receives the switch permission signal (SR17: YES), it switches to the normal operation mode.
[0045] If the control unit 50 does not receive the switching signal (SC17: NO), it continues to operate in the linked operation mode, and if the remote controller 30 does not receive the switching permission signal (SR17: NO), it sends the switching signal again (SR16).
[0046] (Movement of the operation reference part in linked operation mode) The movement of the operation reference portion in the interlocking operation mode will be described mainly with reference to FIGS. In the following description of this embodiment, the initial state is when the crane apparatus 10 is in the stored posture. Therefore, the description will be given assuming that the boom 13 does not deviate from the horizontal posture during operation. The dashed dotted lines IXs, IYs, IZs, IYc, and IXc shown in FIGS. 8, 9, and 11 indicate imaginary straight lines extending along the corresponding coordinate axes Xs, Ys, Zs, Yc, and Xc.
[0047] First, for comparison, the operation in the conventional linked operation mode will be described with reference to FIG. In the conventional interlocking operation mode, the rotational attitude of the work machine coordinate system C2 is fixed in a state where it coincides with the rotational attitude of the reference coordinate system C1. Therefore, even if the rotational attitude of the remote controller 30 changes, the direction of the operation input and the movement direction of the operation reference unit 90 in the reference coordinate system C1 do not coincide.
[0048] For example, when the remote controller 30 is rotated 30° in the +yaw direction from the state where it is aligned with the rotational attitude of the reference coordinate system C1 and an operation input is made in the +YTx direction, the movement reference unit 90 moves linearly toward the rear of the vehicle along the vehicle longitudinal direction. Also, when an operation input is made in the +XTx direction, the movement reference unit 90 moves linearly toward the left side of the vehicle along the vehicle width direction.
[0049] With reference to FIG. 9, the operation in the linked operation mode according to this embodiment will be described. Specifically, the compensation calculation unit 53 performs compensation by rotating the work machine coordinate system C2 from the initial posture around an axis along the Zs axis by a predetermined angle that is set based on the rotation angle of the remote controller 30 around an axis along the Zs axis. Note that because Fig. 9 is a view of the mobile crane 1 as seen from above, the Zs axis is not shown, but the rotation angle around the axis along the Zs axis is expressed by the angle between the imaginary line IYc and the imaginary line IYs and the angle between the YTx axis and the imaginary line IYs.
[0050] In this embodiment, the predetermined angle is set equal to the rotation angle around the Zs axis. Therefore, in the reference coordinate system C1, at least the horizontal orientations of the Xc axis and the XTx axis and the horizontal orientations of the Yc axis and the YTx axis are consistent. Note that in this embodiment, the pitch angle and roll angle of the work machine coordinate system do not change from the initial attitude, and the pitch angle, roll angle, and yaw angle of the remote controller 30 change depending on the holding attitude of the operator.
[0051] By rotationally correcting the work machine coordinate system C2 in this way, the direction of the operation input in the reference coordinate system C1 and the horizontal movement direction of the movement reference unit 90 coincide with each other. For example, when the remote controller 30 is rotated +30° in the yaw direction from the reference attitude and an operation input in the +YTx direction is performed, the operation reference unit 90 moves horizontally in a straight line toward the left rear of the vehicle along a line that intersects with the Ys axis at an angle of 30°. Similarly, when an input in the +X axis direction is performed on the remote controller, the operation reference unit 90 moves horizontally in a straight line toward the left front of the vehicle along a line that intersects with the Xs axis at an angle of 30°.
[0052] As shown in Fig. 10, such linear movement is achieved by interlocking a rotational movement t and an extension / retraction movement e. Therefore, the movement control unit 54 sets the movement direction and movement speed of the rotation motor 14 and tele-cylinder 17 shown in Fig. 3 so that the movement direction Mc1 coincides with the operation command direction MTx1 by combining the rotational movement t and the extension / retraction movement e. The combination of the rotation operation t and the extension / retraction operation e for synthesizing the movement direction Mc1 varies depending on the posture of the crane apparatus 10. For example, when an operation command is transmitted to move the movement reference unit 90 to the front of the vehicle along the longitudinal direction of the vehicle when the movement reference unit 90 is located on the rear right side of the vehicle, the required operation of the actuator AC differs from when a similar operation command is transmitted when the movement reference unit 90 is located on the front left side of the vehicle. Therefore, the operation control unit 54 calculates appropriate swing operation t and extension / contraction operation e using the detection value of the work machine attitude detection unit when generating the operation command.
[0053] Furthermore, when the boom 13 is extended or retracted while keeping the length of the wire rope W constant, the length of the wire rope W hanging down from the tip of the boom 13 changes, and the position of the hook 18 naturally changes. Therefore, in this embodiment, based on the detection value of the boom length detection unit 22, the hook position calculation unit 55 calculates the distance between the hook 18 and the tip of the boom 13, and the operation control unit 54 controls the rotation of the winch 15 so as to maintain a constant distance between the tip of the boom 13 and the hook 18.
[0054] <Effects of the First Embodiment> As explained using Figure 8, in conventional remote control systems for work machines capable of linked operation, the direction in which the operation reference unit 90 moves is fixed regardless of the rotational attitude of the remote controller 30. Therefore, when actually performing operation, the direction of the operation input must be determined taking into account the orientation of the operator and the orientation of the work machine. In contrast, the present invention rotates and adjusts the work machine coordinate system C2 according to the attitude of the remote controller 30 and sets the movement direction of the operation reference unit 90, making it possible to operate it intuitively and easily compared to conventional work machine remote control systems. Furthermore, since only the remote controller attitude detection unit 40 is newly installed in the remote controller 30, and the configuration of the control unit 50 is realized mainly by a program, an increase in the manufacturing cost of the remote controller 30 can be suppressed.
[0055] By applying the present invention, the direction of movement of the operation reference unit 90 can be changed by changing the rotational attitude of the remote controller 30, even while keeping the input direction to the input unit IP constant, making it easy to operate with one hand.
[0056] In particular, when the rotational attitude of the remote controller coordinate system C3 and the rotational attitude of the remote controller 30 are set to coincide with each other, the most intuitive operation is possible. For example, by pointing at the target location to which the load is to be moved on the top of the remote controller 30 and inputting an operation in the +YTx direction into the input unit IP, the load can be moved to the target location. Conversely, to move the load closer to the operator, the remote controller can be used to point at the load and the input unit can be used to input an operation in the -YTx direction, thereby moving the load to the target location. When performing such an operation, the +YTx direction is a direction away from the operator, and the -YTx direction is a direction towards the operator, so the operator's sense of direction and the input direction coincide.
[0057] Furthermore, the remote controller 30 according to the present invention is equipped with three types of sensors as the remote controller attitude detection unit 40, and therefore is able to detect the rotational attitude of the remote controller 30 with high accuracy. In particular, by providing the three-axis geomagnetic sensor 43, there is no need to reset the reference position even when the power to the remote controller 30 is turned off while the mobile crane 1 is not moving, reducing the effort required to set the reference position.
[0058] In the remote control system for a work machine according to the present invention, the control unit 50 is equipped with a hook position calculation unit 55, and based on the calculation results, the operation control unit 54 performs control to maintain a constant distance between the tip of the boom 13 and the hook 18. Here, because the operator of the crane apparatus 10 according to the present invention does not operate each actuator AC individually, he or she is unable to extend or retract the boom 13 at any desired timing, which may result in unintentional movement of the hook 18 up or down. Therefore, by moving the hook 18 up or down at the same time as the boom 13 extends or retracts, such unintentional up or down movement of the hook can be prevented, making operation during linked operations even easier.
[0059] In the work machine remote control system according to the present invention, an initial attitude is set in the work machine coordinate system C2 in order to perform initialization to make the work machine coordinate system correspond to the remote controller coordinate system. After the initialization is complete, the work machine coordinate system C2 is rotationally corrected based on a change in the rotational attitude of the remote controller 30, thereby aligning the direction of the operation input with the direction of movement of the motion reference unit 90. This configuration eliminates the need for constant two-way communication between the remote controller 30 and the control unit 50, reducing the amount of communication traffic. This eliminates the need for high-performance communication devices, and reduces the manufacturing costs of the remote controller 30 and the control unit 50. In addition, because the initial posture is set to follow the reference coordinate system C1, which is set based on the mobile crane 1, it is easy to know the direction in which to hold the remote controller 30 during initialization. Furthermore, because initialization is performed when the remote controller 30 and control unit 50 are paired, it is unlikely to interfere with work.
[0060] <Modification of the first embodiment> In the first embodiment, the predetermined angle used when performing rotational adjustment of the work machine coordinate system C2 was equal to the rotation angle of the remote controller 30 around the axis along the Zs axis, but in the application of the present invention, it is not necessarily necessary to make the predetermined angle equal to the angle of the remote controller 30 around the axis along the Zs axis. Furthermore, if necessary, a predetermined coefficient can be set to determine the amount of compensation, and the work machine coordinate system C2 can be rotated and compensated for by an angle obtained by performing arithmetic operations using the rotation angle of the remote controller 30 and the predetermined coefficient. By performing such rotation compensation, the work machine can be operated simply by inputting data to the input unit IP and manipulating the rotational attitude of the remote controller 30, making it possible to select from a variety of operating methods an operating method suitable for each task. For example, if the coefficient is set to 2, the rotational attitude of the work machine coordinate system is corrected to an angle twice the change in attitude of the remote controller 30, so that even a slight operation can greatly change the direction of movement of the work machine, making it possible to perform a variety of operations with one hand.
[0061] Furthermore, the remote controller 30 shown in the first embodiment is provided with the left stick 34 and the right stick 35 having input axes in the XTx and YTx directions as input units IP, but in applying the present invention, the remote controller 30 does not necessarily have to be provided with such input units IP. For example, even if a toggle switch that allows input only in the YTx direction is provided, it is possible to match the direction of operation input to the input unit IP in the reference coordinate system C1 with the movement direction of the operation reference unit 90. Therefore, the structure of the input unit IP can be applied to the remote control system for a work machine according to the present invention, regardless of the structure, as long as it allows input operation in the YTx direction.
[0062] In the first embodiment, the present invention has been described as being applied to a mobile crane 1 as an example of an industrial machine equipped with a work implement, but application of the present invention is not limited to the mobile crane 1. For example, the present invention may be applied to an aerial work vehicle equipped with a bucket that can accommodate a person as a work implement, or a hydraulic excavator that can be used as a mobile crane. Therefore, in applying the present invention, the hook position calculation unit 55 does not necessarily have to be provided.
[0063] The remote controller 30 described in the first embodiment is equipped with three types of sensors as a remote controller attitude detection unit, but in the application of the present invention, it is not necessarily required to have multiple sensors. This configuration is intended to facilitate highly accurate detection of the rotational attitude of the remote controller 30, and the sensors used in the remote controller attitude detection unit can be changed as desired depending on the usage environment and the characteristics of the industrial machine.
[0064] In the first embodiment, the initial orientation of the work machine coordinate system C2 is set to a rotated orientation in which each of its coordinate axes is aligned with each of the coordinate systems of the reference coordinate system C1, but in the application of the present invention, the initial orientation of the work machine coordinate system C2 is not limited to this rotated orientation. In the application of the present invention, the initial orientation can be set to any orientation as long as initialization is possible to associate the rotational orientation of the work machine coordinate system C2 with the rotational orientation of the remote controller coordinate system C3.
[0065] In the first embodiment, the remote controller 30 has the left stick 34 and the right stick 35 as the input unit IP, but in the application of the present invention, the input unit IP does not necessarily have to be a joystick. For example, even if the input unit is a single push button switch that only inputs operation in the -Y direction, by pointing the top of the remote controller 30 toward the operation reference unit 90, the operation reference unit 90 will move toward the operator. Conversely, if the input unit is a single push button switch that inputs operation in the +Y direction, the operation reference unit 90 will move toward the side toward which the top of the remote controller 30 is pointed upon input. Even with this configuration, the crane apparatus 10 can be operated with a simple operation regardless of changes in the relative angle between the crane apparatus 10 and the remote controller 30, and work can be continued smoothly.
[0066] Second Embodiment The second embodiment will be described mainly with reference to Figures 11 to 14. Only the parts that differ between the second embodiment and the first embodiment will be described in detail, and a description of the parts that are common to both will be omitted. Specifically, in the first embodiment, rotational adjustment of the work machine coordinate system C2 was performed by changing the rotational posture around the Zc axis, but in the second embodiment, the difference is that rotational adjustment is performed by rotating the work machine coordinate system C2 in three dimensions.
[0067] <Remote control system operation> (Rotation compensation) With reference to FIG. 11, the operation when rotation compensation around the YTx axis is performed will be described. When the remote controller 30 is rotated around the YTx axis, the compensation calculation unit 53 rotates the work machine coordinate system C2 around the Yc axis by an angle equal to the rotation angle of the remote controller 30 around the YTx axis. For example, as shown in Figure 10, when the remote controller 30 is rotated +30° in the roll direction, the work machine coordinate system C2 is also rotated +30° in the roll direction for correction. In other words, a correction is performed to match the rotational attitude of the remote controller coordinate system C3 and the rotational attitude of the work machine coordinate system C2 in the reference coordinate system C1. In this state, when the right stick 35 is operated to input an operation in the +ZTx direction, the motion reference portion 90 tilts 30 degrees from the vertical direction and moves in the upper right direction of the vehicle.
[0068] In addition, since the boom 13 extends when performing this operation, the operation control unit 54 rotates the winch 15 so that the amount of extension of the boom 13 is equal to the amount of unwinding of the wire rope W, thereby controlling the distance between the tip of the boom 13 and the hook 18 to be constant.
[0069] (Changes in rotation compensation due to changes in the attitude of the remote control device) Changes in rotation compensation of the work machine coordinate system C2 in response to changes in the rotational attitude of the remote controller 30 will be described mainly with reference to FIGS. The initial state is a state in which the crane apparatus 10 is in the stored position and pairing between the remote controller 30 and the control unit 50 is completed.
[0070] 12, when the operator sets the interlocking operation mode using the method described in the first embodiment, the rotational attitude of the work machine coordinate system C2 is rotationally corrected so that it matches the rotational attitude of the remote controller coordinate system C3. Note that the rotational attitudes of the remote controller 30 and the work machine coordinate system C2 at this time are defined as (Φ1, θ1, Ψ1). That is, the rotational adjustment causes the orientations of the XTx and Xc axes in the reference coordinate system C1, the YTx and Yc axes in the reference coordinate system C1, and the ZTx and Zc axes in the reference coordinate system C1 to coincide with each other. In this state, when an operation command direction MTx2 having components in the XTx and YTx directions in the remote control coordinate system C3 is input to the left stick 34, the motion reference unit 90 also moves in a movement direction Mc2 having components in the Xc and Yc directions in the work machine coordinate system C2.
[0071] 13, such linear movement is achieved by performing a pivoting operation t, a telescoping operation e, and a raising and lowering operation r in conjunction with each other. Therefore, the operation control unit 54 sets the operation direction and operation speed of each actuator AC so that the movement direction Mc2, which is a combination of the pivoting operation t, the telescoping operation e, and the telescoping operation r, coincides with the operation command direction MTx2. In this embodiment as well, the operation control unit 54 uses the detection values of the work machine attitude detection unit 20 when generating an operation command to calculate appropriate swing operation t, extension / retraction operation e, and elevation / tilt operation r.
[0072] As shown in Fig. 14, when the rotational attitude of the remote controller 30 is changed to (Φ2, θ2, Ψ2) while maintaining the operation command direction MTx2, the work machine coordinate system C2 is also rotationally corrected and its rotational attitude becomes (Φ2, θ2, Ψ2). At this time, the direction of the operation command direction MTx2 in the remote controller coordinate system C3 and the direction of the movement direction Mc2 in the work machine coordinate system C2 are maintained. However, since the direction in the reference coordinate system C1 changes, the movement direction of the motion reference unit 90 as seen by the operator changes. In this way, by changing the attitude of the remote controller 30 while maintaining the operation command, it is possible to continuously change the direction of movement of the motion reference unit 90.
[0073] It is assumed that three-dimensional coordinates are used to control the direction of movement of the operation reference point 90, and the work machine coordinate system is subjected to rotational correction. 12 and 13, in a state before the rotation correction of the work machine coordinate system C2, the starting point of the operation reference part 90 is shown by coordinates (Xc00, Yc00, Zc00). Then, the first point after moving a predetermined distance is shown by coordinates (Xc01, Yc01, Zc01). While the movement reference unit 90 moves from the starting point to the first point, a movement correction process is performed to improve the linearity of the movement. This movement correction process has been used conventionally and will not be described in detail, but for each predetermined control cycle, the error between the target coordinates through which the movement reference unit 90 would pass if it were to move in an ideal straight line and the actual coordinates calculated based on the detection results of the work machine attitude detection unit 20 is calculated, and the movement amount of the actuator AC is corrected based on this error.
[0074] When the rotational attitude of the remote controller 30 is changed to (Φ2, θ2, Ψ2), the work machine coordinate system C2 is rotationally corrected as described above. Therefore, as shown in Figure 14, the first point is recalculated to coordinates (Xc11, Yc11, Zc11). Then, target coordinates (Xc12, Yc12, Zc12) are set based on the movement direction Mc2 in the work machine coordinate system C2 after the attitude change. In this way, the change in the rotational attitude of the work machine coordinate system C2 also changes the coordinate values of the three-dimensional coordinate system where the motion reference unit 90 is located. Therefore, the target coordinates and actual coordinates are recalculated, and the motion correction process described above is continued.
[0075] <Effects of the second embodiment> When the remote control system for the work machine according to the second embodiment is used, in addition to the effects achieved by applying the remote control system for the work machine according to the first embodiment, it is also possible to move the operation reference unit 90 in the vertical direction, thereby enabling even more intuitive and diverse operations.
[0076] The remote control system for a work machine shown in this embodiment, in which the rotational attitudes of the work machine coordinate system C2 and the remote controller coordinate system C3 coincide, is particularly suitable for industrial machinery in which the work machine is frequently moved up and down. This is because the greater the difference in elevation between the movement reference unit 90 and the operator, the less visible the movement reference unit is to the operator, making operation more difficult. However, according to the present invention, even when the difference in elevation between the operator and the movement reference unit is large, the work machine can be operated simply by pointing at the destination point with the remote controller 30 and inputting a one-way operation, thereby achieving the above-mentioned effects.
[0077] By performing rotational correction on the work machine coordinate system C2, it becomes possible to easily reuse the conventional operation control using three-dimensional coordinates in the work machine coordinate system C2, thereby reducing the system design and modification costs.
[0078] <Modification of the second embodiment> In the second embodiment, a configuration has been described in which rotation compensation for three-dimensionally rotating the work machine coordinate system C2 is performed on all three axes, i.e., roll, pitch, and yaw. However, when applying the present invention, it is not necessarily necessary to perform rotation compensation on all three axes, and a configuration may be adopted in which the amount of compensation can be changed for each coordinate axis of the work machine coordinate system C2 depending on the target work. In other words, when performing rotation compensation on the work machine coordinate system C2, the coefficient for determining the amount of compensation for any one axis may be set to 0, and three-dimensional rotation may be performed while fixing one of the axes. For example, even if rotation compensation in the roll direction is not performed, there is no effect on operation input along the YTx axis, and the operation reference unit 90 can be moved up and down along the vertical direction regardless of the roll angle of the remote controller 30. By enabling such a configuration, the selectable operation methods become more diverse, leading to improved operability. [Explanation of symbols]
[0079] 1...Mobile crane, 10...Crane device, 11...Slewing device, 12...Column, 13...Boom, 18...Hook, 20...Work machine attitude detection unit, 21...Boom angle detection unit, 22...Boom length detection unit, 23...Slewing angle detection unit, 24...Wire length detection unit, 30...Remote control device, 34...Left stick, 40...Remote control device attitude detection unit, 50...Control unit, 52...Reference attitude setting unit, 53...Compensation calculation unit, 54...Movement control unit, 55...Hook position calculation unit, AC...Actuator, C1...Reference coordinate system, C2...Work machine coordinate system, C3...Remote control device coordinate system, IP...Input unit
Claims
1. A remote control system for a work machine, comprising: an industrial machine having a work machine rotatable around a pivot axis along a vertical direction and a control unit for controlling the work machine; and a remote controller for operating the work machine, wherein a single operation input causes a plurality of actuators of the work machine to be operated in combination, thereby enabling linked operation to linearly move an operation reference part set at a predetermined position of the work machine, a reference coordinate system based on the industrial machine; a work machine coordinate system in which a predetermined initial attitude is set with the work machine as a reference; a remote controller coordinate system is set based on the remote controller and has a fixed rotational attitude relative to the remote controller; The work machine includes a work machine attitude detection unit that detects its own attitude, the control unit includes a receiving unit, a reference attitude setting unit, a compensation calculation unit, and an operation control unit; the remote controller includes an input unit, a remote controller attitude detection unit, and a transmission unit; A movement direction of the movement reference unit in the work machine coordinate system is input to the input unit, the remote controller attitude detection unit detects a rotational attitude of the remote controller in the reference coordinate system; the transmitter transmits the input value of the input unit and the detection value of the remote controller attitude detection unit; the receiving unit receives the information transmitted from the transmitting unit, the reference attitude setting unit sets, as a reference attitude, a detection value of the remote controller attitude detection unit when an initial attitude of the work machine coordinate system in the reference coordinate system and a rotational attitude of the remote controller coordinate system in the reference coordinate system coincide with each other; the compensation calculation unit performs a calculation to rotate and compensate the work machine coordinate system from the initial attitude to a predetermined rotational attitude corresponding to the rotational attitude of the remote controller coordinate system in the reference coordinate system, based on the detection value of the remote controller attitude detection unit and the reference attitude; The operation control unit controls the direction and speed of movement of the actuator based on the detection value of the work machine attitude detection unit, the input value of the input unit, and the calculation result of the compensation calculation unit.
2. 2. The remote control system for a work machine according to claim 1, wherein the predetermined rotational attitude is a rotational attitude obtained by rotating the work machine coordinate system from the initial attitude around an axis along the vertical direction in the reference coordinate system by a predetermined angle that is set based on a rotation angle of the remote control unit coordinate system around an axis along the vertical direction in the reference coordinate system.
3. 3. The remote control system for a work machine according to claim 2, wherein the predetermined angle is equal to a rotation angle of the remote controller coordinate system around an axis along the vertical direction in the reference coordinate system.
4. 2. The work machine remote control system according to claim 1, wherein the predetermined rotational attitude is a rotational attitude obtained by three-dimensionally rotating the work machine coordinate system from the initial attitude by a predetermined angle set around each of the three rotational axes based on the rotation angles of the remote controller coordinate system around the three rotational axes expressed by Euler angles in the reference coordinate system.
5. 5. The remote control system for a work machine according to claim 4, wherein the predetermined angles set for each of the three rotation axes are angles at which the rotational attitude of the remote controller coordinate system coincides with the rotational attitude of the work machine coordinate system rotated three-dimensionally.
6. 6. The remote control system for a work machine according to claim 1, wherein the input unit has input axes oriented along two of the coordinate axes of the remote controller coordinate system.
7. The work machine includes an extendable boom and a hook connected to a wire rope wound around a winch and hanging down from the tip of the boom, the operation reference portion is set at a tip portion of the boom, the work machine attitude detection unit includes a wire length detection unit and a boom length detection unit, the control unit further includes a hook position calculation unit that calculates a distance between the tip of the boom and the hook based on detection values of the wire length detection unit and the boom length detection unit, 6. The remote control system for a work machine according to claim 1, wherein the operation control unit, during the linked operation, operates the winch so as to maintain a constant distance between the tip of the boom and the hook based on the detection value of the boom length detection unit and the calculation result of the hook position calculation unit.
8. 6. The remote control system for a work machine according to claim 1, further comprising a triaxial acceleration sensor, a triaxial angular velocity sensor, and a triaxial geomagnetic sensor as the remote control attitude detection unit.
9. 6. A remote control system for a work machine according to claim 1, wherein the predetermined initial attitude of the work machine coordinate system is set to a rotational attitude when the work machine itself is aligned with the rotational attitude of the reference coordinate system.
Citation Information
Patent Citations
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