Machine Safety Zone Control

Abstract

A work machine (1) is disclosed. The work machine has a machine control (24) for controlling movement of the work machine in an operational mode (34) of the machine control. The work machine also has a processing unit (13) having a detection unit (14). The detection unit is located on the work machine and is used to detect a target object (15) within a safety zone (16). The processing unit transmits a detection signal (21) to the machine control when a target object is detected within the safety zone, and the machine control enters a safety mode (35) from the operational mode when the detection signal is received. In the safety mode, movement control of the work machine is disabled.

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE This disclosure relates generally to work machines, and more particularly to work machines having machine controls with safety modes for use in the construction industry. [Background technology]

[0002] In construction, construction equipment such as excavators and loader vehicles are typically utilized to remove earth materials and load them onto trucks. Generally, the truck returns to a position near the excavator where the earth materials excavated by the excavator are loaded. Sometimes, a human is required to be near the construction equipment to help guide the truck and complete manual construction tasks near the operating construction equipment. However, it can be difficult for the operator of the construction equipment to see all the workers around the construction equipment at night, in adverse weather conditions, or from blind spots present on the construction equipment. This creates a dangerous condition where workers may be injured by the operating construction equipment.

[0003] US Patent No. 11,028,553 discloses a construction machine having a distance sensor, a displacement detection, and a position information acquisition unit. The distance sensor has a predetermined field of view and acquires distance image data showing the distance distribution of the environment around the operator cab. The displacement detection unit compares the comparative position information of the boom with the initial position information of the boom to detect the displacement of the distance sensor relative to the operator cab.

[0004] While effective, there remains a need for improved safety controls for construction machines, such as construction machines in the construction industry. Summary of the Invention

[0005] In accordance with the present disclosure, a work machine is disclosed. The work machine has a machine control for controlling movement of the work machine in a machine control operational mode. The work machine also has a processing unit having a detection unit. The detection unit is located on the work machine and is used to detect a target object within a safety zone. The processing unit transmits a detection signal to the machine control when a target object is detected within the safety zone, and the machine control enters a safety mode from the operational mode when the detection signal is received. In the safety mode, movement of the work machine is disabled.

[0006] According to another aspect of the present disclosure, a safety control system for a work machine is disclosed. The safety control system includes a machine control for controlling movement of the work machine, the machine control including a mode switching unit. The safety control system further includes a processing unit having a detection unit, the detection unit being located on the work machine. The processing unit detects a target object within a safety zone using the detection unit, and upon detecting the target object, the processing unit sends a detection signal to the mode switching unit of the machine control. Upon receiving the detection signal, the mode switching unit switches the machine control from an operating mode to a safety mode, and movement of the work machine is disabled in the safety mode.

[0007] According to a further aspect of the disclosure, a method of controlling a safety-related mode of a work machine is provided. The method includes controlling movement of the work machine with a machine control. The machine control provides full power to the motor and hydraulic system when the work machine control is in an operating mode and the motor and hydraulic system move the work machine based on input received at the operator control. The method further includes monitoring the safety zone with a processing unit of the work machine to detect a target object within the safety zone. The processing unit has a detection unit located on the work machine. The processing unit transmits a detection signal to the machine control when a target object is detected in the safety zone. The method then places the machine control in a safety mode when the detection signal is received at the machine control. Movement control of the work machine is disabled after the machine control is placed in the safety mode.

[0008] These and other aspects and features of the present disclosure are better understood when read in conjunction with the accompanying drawings. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a top view of an exemplary work machine having safety zones in accordance with this disclosure. [Diagram 2] FIG. 2 is a front view of a target object according to the present disclosure. [Diagram 3] FIG. 3 is a block diagram of a safety control system for a work machine in accordance with the present disclosure. [Figure 4] FIG. 4 is a flow chart illustrating a method for controlling a safety-related mode of a work machine in accordance with the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] 1, there is shown a top view of a work machine 1. Work machine 1 may embody a stationary or mobile machine that performs some type of operation associated with an industry such as construction, mining, agriculture, transportation, or other industries known to utilize heavy machinery. For example, work machine 1 may be an excavator as shown, or an earth moving machine such as a motor grader, backhoe, dozer, loader, truck, or any other earth moving machine.

[0011] Work machine 1, shown as a hydraulic excavator in the exemplary embodiment of Figure 1, includes a base frame 2 supporting a rotating frame 3 rotatably mounted to the base frame 2, the rotating frame 3 being rotatable up to 360 degrees relative to the base frame 2. The base frame 2 is supported on a crawler-type undercarriage 4, although in another exemplary embodiment the undercarriage 4 may support wheels or other mobile support means. An operator cab 5, including operator controls 6 (Figure 3) necessary to operate the work machine 1, is mounted on the rotating frame 3.

[0012] The rotating frame 3 has a motor 7, in this exemplary embodiment an internal combustion engine such as a diesel engine is used as the engine for the power generation device, although in other exemplary embodiments another power generation device is used such as an electric motor, a hybrid motor, etc. The motor 7 is used to power the running body 4 to power the movement of the work machine, such as moving the work machine 1 over a surface.

[0013] In the exemplary embodiment of FIG. 1 , the work tool 8 is mounted to the rotating frame 3. Specifically, the work tool 8 is liftably and lowerably mounted to the rotating frame 3 and includes a boom 9, an arm 10 pivotably mounted to a distal end of the boom 9, and a bucket 11 pivotably mounted to a distal end of the arm 10. The bucket 11 can hold a predetermined held object, such as an excavation or soil material. The positions of the boom 9, arm 10, and bucket 11 are controlled by a motor and hydraulic system 12, including the motor 7 and any hydraulic actuators, cylinders, and additional hydraulic motors (not shown) mounted to the rotating frame 3, the boom 9, the arm 10, and the bucket 11. More specifically, the motor and hydraulic system 12 can raise and lower the boom 9 pivotably mounted to the rotating frame 3, raise and lower the arm 10 pivotably mounted to the boom 9, and raise and lower the bucket 11 pivotably mounted to the arm 10.

[0014] The work machine also has a processing unit 13 (FIG. 3) that includes a detection unit 14 disposed on the work machine 1. The detection unit 14 may include a camera or sensor disposed about the work machine 1, or may include one or more cameras or sensors, and may simultaneously monitor a predetermined field of view (or detection range) and a detection range extending up to 360 degrees of the area around the work machine 1. The detection unit 14 may be one or more 2D cameras, 3D stereo cameras, LiDAR cameras, ultrasonic distance sensing sensors, or millimeter wave radar, or may include a combination of any two or more of these cameras / sensors.

[0015] In one exemplary embodiment, the processing unit 13 includes a detection unit 14 for detecting a target object 15 within a safety zone 16 of the work machine 1. The safety zone 16 may be an area within a safety zone boundary 17, for example as shown in FIG. 1, where the safety zone boundary surrounds the work machine 1 and encompasses all sides of the work machine 1. In one exemplary embodiment, the safety zone boundary 17 may be a predefined distance around the work machine 1 or may be determined by the detection range of the detection unit 14. The detection unit 14 is configured to detect the target object 15 after it has passed the safety zone boundary 17 and is within the safety zone 16. In another exemplary embodiment, the safety zone 16 is dynamic and instead of encompassing the entire work machine 1 as shown in FIG. 1, the safety zone is the operating range of the work machine 1, in particular the operating range of the rotating frame 3 or the work tool 8. In this example, the operating range of the rotating frame 3 or the work tool 8 is all the area surrounding the rotating frame 3 and the work tool 8 that can be physically contacted by the rotating frame 3 and the work tool 8 when they are rotated, raised or lowered to their physical maximum. Thus, for example, if the rotating frame 3 of the embodiment of FIG. 1 is rotated 90 degrees to the right, the range of motion of the work tool 8 changes to cover the work tool 8 on the right side 18 of the work machine 1 instead of the front side 19, but the range of motion of the rotating frame 3 still remains the same as when it is able to rotate 360 ​​degrees.

[0016] The detection unit 14, in one exemplary embodiment, is a two-dimensional (2D) imaging sensor, such as one or more 2D cameras (imaging cameras) mounted on the work machine 1. In this embodiment, the two-dimensional imaging sensor is used to detect and identify surface characteristics of a target object 15 within the field of view of the sensor. The 2D imaging camera operates by projecting a broad beam of light towards the safety zone 16 and collecting reflected light reflected from surfaces and objects (e.g., the target object 15) within the field of view of the receiver. In another exemplary embodiment, the imaging camera may sweep a beam of light across the safety zone 16 in an oscillatory manner to collect linear image data that is analyzed to identify the target object 15. For example, the detection unit 14 may continuously capture picture frames of the safety zone 16, and the processing unit 13 may continuously process the captured picture frames by comparing the captured picture frames to known images of the target object stored on a database 20 (FIG. 3). The database 20 may be a hard drive operably connected to the processing unit and located on the work machine 1, or it may be a remote server operably connected wirelessly to the processing unit. Upon detection of a target object 15 in a captured picture frame, processing unit 13 transmits a detection signal 21 (FIG. 3) to machine control 24 (FIG. 3). In another embodiment, processing unit 13 processes an image captured by detection unit 14 using a neural network 22 (FIG. 3) to determine whether a target object 15 is present in the captured image, and upon detection of a target object 15 in the image, processing unit 13 transmits a detection signal 21.

[0017] Alternatively, detection unit 14 is a 2D camera that projects a stationary, substantially planar beam of light across safety zone 16 and collects data on objects passing through the beam. Typically, the 2D image sensor performs grayscale or red-green-blue (RGB) analysis on pixel data generated based on the reflected light to obtain two-dimensional image data, or field of view, of safety zone 16 that can be analyzed by processing unit 13 to identify target object 15. For example, detection unit 14 uses 2D to look at wavelength light frequencies, and processing unit 13 processes the image data to detect predetermined wavelength light frequencies of target object 15 to detect target object 15.

[0018] In another exemplary embodiment, the detection unit 14 is a three-dimensional (3D) image sensor, also known as a time-of-flight (TOF) sensor, designed to generate distance information as well as two-dimensional shape information of the target object 15 within the safety zone 16 (or field of view). In one embodiment, the TOF sensor determines the distance of the target object 15 using a phase shift monitoring technique, where a beam of light is emitted within the safety zone 16 and the measured phase shift of the light reflected from the target object 15 relative to the emitted light is converted into a distance value. In a further embodiment, a TOF sensor using pulsed light illumination measures the time elapsed between the emission of a light pulse into the safety zone 16 and the receipt of the reflected light pulse at an optical receiver of the sensor.

[0019] Returning to FIG. 2, in the embodiment of FIG. 2, the target object 15 is a safety vest 23. The safety vest 15 is worn by a construction worker operating near the work machine 1. When the safety vest 23 passes the safety zone boundary 17 and enters the safety zone 16, the processing unit 13 using the detection unit 14 detects the safety vest 23 and transmits a detection signal 21 to the machine control 24. The detection unit 14 may detect the safety vest 14 by capturing an image of a pattern 25, such as stripes, using reflective tape or other predefined pattern on the safety vest 23, or may detect a predefined wavelength light frequency of a predefined color 26 on the safety vest. In one exemplary embodiment, the color is safety orange, but any predefined color 26 may be preprogrammed by the processing unit to be the target object 15. In another exemplary embodiment, the target object 15 is not a safety vest 23, but a different construction machine, clothing, or object having a predefined pattern 25 or color 26 that is recognized by the processing unit 13 as the target object 15.

[0020] 4, there is shown a schematic block diagram of a safety control system 27 of the work machine 1. The safety control system 27 is designed to detect a target object 15 within the safety zone 16 and disable all machine movement including the boom 9, arm 10, bucket 11, running body 4, and rotating frame 3. The safety control system 27 includes the machine control 24, the processing unit 13, and an override signal 28 that is received at a mode switching unit 30 of the machine control 24.

[0021] The machine control 24 is used to control the positioning of the work tool 8 (including the boom 9, arm 10, and bucket 11, or any work tool 8 of any construction machine), any rotating frame 3 of the work machine 3, and any running body 4 for positioning the work machine 1. To control these positioning, the machine control 24 first receives a movement signal 31 from the operator control 6 located inside the operator cab 5 based on an input 32 received at the operator control 6 from the operator of the work machine 1. After receiving the movement signal 31, the machine control 24 sends an actuation signal 33 to the motor and hydraulic system 12. Upon receiving the actuation signal 33, the motor and hydraulic system 12 actuates the hydraulic cylinders to move the work tool 8. Upon receiving the actuation signal, the motor 7 of the motor and hydraulic system 12 may be used to power the movement of the running body 4 and rotating frame 3, or any other movement of the work machine 1 depending on the type of construction machine used.

[0022] The machine control 24 defaults to an operating mode 34 in which all power from the motor and hydraulic system 12 is sent to the running body 4, the work tool 8, and the rotating body 3 to provide full speed movement of the work machine 1. However, if the processing unit 13 detects a target object 15 within the safety zone 16, the processing unit sends a detection signal 21 to the machine control 24. Upon receiving the detection signal 21, the machine control enters a safety mode 35. Upon entering the safety mode 35, the machine control 24 sends a disable signal 36 to the motor and hydraulic system 12, all movement and movement control of the work machine 1, including the running body 4, the work tool 8, and the rotating frame 3, are disabled, and no power is provided to the running body 4, the work tool 8, and the rotating frame 3, despite any input 32 received at the operator control 6. Additionally, in the safety mode 35, the machine control sends a status signal 37 to the operator control 6 indicating that the machine control of the work machine 1 has been disabled, and the status signal is displayed on the operator control 6 that the machine has entered the safety mode 35. This status signal may be text or symbol based, or may be a status signal displayed on the screen of the operator control 6, or may include an illuminated status light. Further, in one exemplary embodiment, after entering safety mode 35, if the target object 15 is no longer detected by the processing unit 13 within the safety zone 16, safety mode 35 is disabled and the machine control 24 returns to operating mode 34, returning full motion control and power to the motors and hydraulic systems.

[0023] After entering the safety mode 35, in one embodiment, the safety mode 35 is disabled by entering a passcode input 38 on the operator control 6. Upon receiving the passcode input 38, an override signal 28 is sent from the operator control 6 to the mode switching unit 30 of the machine control 24, causing the machine control 24 to return from the safety mode 35 to the operating mode 34. In one exemplary embodiment, the passcode input 38 may be a passcode entered by a maintenance worker or operator of the work machine 1 on a display or keypad on the operator control 6 or on a maintenance panel on the work machine 1. Additionally, the passcode input 38 may be a key card, key, or other input device (not shown) that includes the passcode input 38 entered on the work machine 1.

[0024] Moreover, in another exemplary embodiment, machine control 24 is operatively connected to a transceiver 42 located on work machine 1. After entering safety mode 35, machine control 24 enters operational mode 34 after receiving override signal 28 from transceiver 42. Prior to being received by transceiver 42, override signal 28 is wirelessly transmitted over network 43 from computer server system 44. Computer server system 44 includes a work machine monitoring program 45 for receiving and monitoring diagnostic data for work machine 1, including receiving alerts when work machine 1 enters safety mode 35. [Industrial Applicability]

[0025] In general, the teachings of the present disclosure may find applicability in many industries, including, but not limited to, construction machinery, or the like. More specifically, the teachings of the present disclosure may find applicability in any industrial safety control system for a work machine having a safety-related mode.

[0026] In one such operation, according to the scope of the present disclosure, when the presence of a construction worker is detected near the operating range of the work machine, it is desirable to disable the work machine and enter a safety mode to prevent injury to the construction worker. However, sometimes equipment is damaged and an erroneous detection signal is sent to the machine control of the work machine, preventing the work machine from being able to disable the safety mode and causing the work machine to move.

[0027] 4, with continued reference to FIGS. 1-3, a flow chart illustrating an exemplary method 100 for controlling at least one safety-related mode of the work machine 1 is shown. At block 102, the machine control 24 controls the movement of the work machine 1 and provides full power to the motor and hydraulic system 12 when the machine control 24 is in the operating mode 34. The movement is based on an input 32 received at the motion control 6 of the work machine 1. At block 104, the safety zone 16 of the work machine 1 is monitored at the processing unit 13 to detect a target object 15 within the safety zone 16. The processing unit 13 includes a detection unit 14 located on the work machine 1. The processing unit 13 transmits a detection signal 21 to the machine control 24 when the target object 15 is detected within the safety zone 16. At block 106, after receiving the detection signal 21, the machine control 24 is placed from the operating mode 34 to the safety mode 35. In the safety mode 35, the movement control of the work machine 1 is disabled at block 108. The safety mode 35 may be overridden when an override signal 28 is received at the machine control 24 and the work machine 1 enters the operating mode 34 .

[0028] Although the foregoing text has described detailed descriptions of many different embodiments, it should be understood that the legal scope of protection is defined by the language of the claims at the end of this patent. The detailed description should be construed as merely exemplary and will not describe all possible embodiments, as doing so would be impractical, if not impossible. Numerous alternative embodiments can be implemented using either current technology or technology developed after the filing date of this patent, which are also within the scope of the claims that define the scope of protection.

Claims

1. A work machine (1), a machine control (24) for controlling movement of the work machine, the machine control having an operating mode (34); 1. A work machine comprising: a processing unit (13) including a detection unit (14) disposed on the work machine configured to detect a target object (15) within a safety zone (16), the processing unit transmitting a detection signal (21) to the machine control when the target object is detected within the safety zone, the machine control entering a safety mode (35) from the operating mode when the detection signal is received at the machine control, and movement control of the work machine being disabled in the safety mode.

2. The work machine of claim 1 , wherein the safety zone surrounds the work machine and is an operating envelope of the work machine.

3. 3. The work machine of claim 2, wherein the detection unit is one or more cameras disposed on the work machine configured to continuously monitor the safety zone, and the processing unit transmits the detection signal upon detection of the target object within the monitored safety zone.

4. 4. The work machine of claim 3, wherein the processing unit processes images captured by the detection unit using a neural network (22) to determine whether the target object is present within the image, and upon detection of the target object in the image, the processing unit transmits the detection signal.

5. 2. The work machine of claim 1, wherein the target object has a predetermined pattern (25) or a predetermined color (26), and the target object is detected by the predetermined pattern or predetermined color.

6. 2. The work machine of claim 1, wherein after entering the safety mode, the machine control returns to the operating mode upon receiving a passcode entry (38) on an operator control (6) of the work machine.

7. 2. The work machine of claim 1, wherein the machine control is operably connected to a transceiver (42) and, after entering the safety mode, the machine control is configured to return to the operating mode upon receiving an override signal (28) on the transceiver.

8. A safety control system (FIG. 3) for a work machine (1), comprising: A work machine according to claim 1 ; said machine control (24) further comprising a mode switching unit (30); an override signal (28) received at the mode-changing unit, the mode-changing unit switching the machine control from the safety mode (35) back to the operating mode (34) when the override signal is received.

9. 9. The safety control system of claim 8, wherein the override signal is transmitted from the operator control of the work machine to the mode change unit upon receiving a passcode entry (38) on an operator control (6).

10. A method for controlling at least one safety-related mode (35) of a work machine (1), comprising the steps of: controlling movement of the work machine with a machine control (24), the machine control providing full power to the motor and hydraulic system (12) when the machine control is in an operating mode (34), the motor and hydraulic system (35) providing the movement of the work machine based on inputs (32) at an operator control (6) of the work machine; monitoring a safety zone (16) with a processing unit (13) of the work machine to detect a target object (15) within the safety zone, the processing unit including a detection unit (14) disposed on the work machine, the processing unit transmitting a detection signal (21) to the machine control when the target object is detected within the safety zone; upon receiving said detection signal at said machine control, placing said machine control in a safety mode (35); disabling movement control of the work machine when the machine control enters the safety mode.

Images