Maintenance System

Abstract

A maintenance system (150) and method for controlling a machine (100) including multiple operation modes is disclosed. The multiple operation modes include a normal mode and a hazard detection mode. The maintenance system (150) may include a controller (154) configured to receive authentication data when the machine (100) is in the hazard detection mode, and to enable movement of the machine (100) at a reduced machine speed based on the authentication data, the reduced machine speed being less than 50% of the normal machine speed available to the machine (100) when the operation mode is the normal mode, and the hazard detection mode prevents movement of the machine (100).

Description

[Technical field]

[0001] The present disclosure relates generally to maintenance and servicing systems, and more particularly, to maintenance and servicing systems for heavy equipment. [Background technology]

[0002] Machines, especially heavy machinery, with control systems that include personnel or object detection sensors can present challenges for maintenance or troubleshooting. The control system may prevent the machine from moving during planned maintenance or troubleshooting because the sensors detect a person, object, wall, or another machine in close proximity to the machine and trigger a disable of the machine. This can happen in a maintenance yard or in the field. This can also occur when the control system is being calibrated / commissioned. When this happens, the machine cannot be moved or operated.

[0003] U.S. Patent No. 9,139,983 issued on September 22, 2015 discloses an engine electronically controlled by a control device, a hydraulic motor for traveling driven by pressurized oil delivered from a hydraulic pump, and a travel speed switching member for switching the travel speed to at least two stages, low speed and high speed, by the hydraulic motor. The control device includes an output reduction determination unit for determining whether the amount of fuel injection supplied to the engine is restricted and the engine output is in a decreasing state, and a low speed control unit for controlling the travel speed to a low speed state that remains lower than the high speed state even if the travel speed switching member is switched to the high speed side when the engine output is in a decreasing state. A better system is desired. Summary of the Invention

[0004] In one aspect of the present disclosure, a maintenance system for a machine including a plurality of operation modes is disclosed. The plurality of operation modes include a normal mode and a hazard detection mode. The maintenance system may include a controller configured to receive authentication data when the machine is in the hazard detection mode, and enable movement of the machine at a reduced machine speed based on the authentication data, the reduced machine speed being less than 50% of a normal machine speed available to the machine when the operation mode is in the normal mode, and the hazard detection mode prevents movement of the machine.

[0005] In another aspect of the present disclosure, a method of controlling a machine having multiple operating modes is disclosed. The multiple operating modes may include a normal mode, a hazard detection mode, and an off mode. The method may include receiving, by the controller, authentication data after activation of the hazard detection mode, and enabling, by the controller, movement of the machine at a reduced machine speed based on the authentication data, the reduced machine speed being less than 50% of the normal machine speed available to the machine when the operating mode is the normal mode.

[0006] In yet another aspect of the disclosure, a system for an excavator is disclosed that includes multiple operation modes. The operation modes include a normal mode, a hazard detection mode, and an off mode. The hazard detection mode prevents movement of the excavator or operation of a hydraulic actuator disposed on the excavator. The system may include a controller configured to receive authentication data when the excavator is in the hazard detection mode, and based on the authentication data, reduce power delivered to a hydraulic power system disposed on the excavator to enable movement of the excavator or operation of the hydraulic actuator at a reduced machine speed, the reduced machine speed being less than 50% of a normal machine speed available to the excavator when the operation mode is in the normal mode, and the reduced actuator speed being less than 50% of a normal actuator speed available to the actuator when the operation mode is in the normal mode. Here, the controller may be configured to enable movement of the excavator or operation of the actuator during an enablement period or until the operation mode changes from the hazard detection mode to the off mode and the excavator is subsequently restarted. The hazard detection mode is triggered in response to the detection of a hazard, including a person, animal, wall, barrier, plant, object or machine. [Brief description of the drawings]

[0007] [Figure 1] FIG. 1 is a perspective view of an exemplary machine that may include a maintenance system in accordance with the present disclosure. [Diagram 2] FIG. 2 is a block diagram of an embodiment of a maintenance system for use with the example machine of FIG. [Diagram 3] FIG. 3 is a flow diagram of an exemplary method according to the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] Reference will now be made in detail to certain embodiments or features, examples of which are illustrated in the accompanying drawings. Generally, corresponding reference numerals are used throughout the drawings to refer to the same or corresponding parts unless otherwise specified.

[0009] 1 illustrates one embodiment of a machine 100 that may incorporate features of the present disclosure. The exemplary machine 100 may be a vehicle, such as an excavator 102. Although the following detailed description and drawings are made with reference to an excavator 102 as the exemplary machine 100, the teachings of the present disclosure may be used with other machines 100, including, but not limited to, backhoe loaders, hydraulic mining shovels, and the like.

[0010] The excavator 102 may include an upper carriage 104 rotatably connected to a lower carriage 106. The upper carriage 104 rotates in both a clockwise and counterclockwise direction. The upper carriage 104 includes an operator cabin 108 and a body 110. The lower carriage 106 includes one or more ground engaging units 112. In the exemplary embodiment shown in FIG. 1, the ground engaging units 112 are track assemblies 114. Those skilled in the art will appreciate that the machine 100 further includes a power source 116 (e.g., an engine), a propulsion system 117, and a hydraulic power system 119. The propulsion system 117 includes the ground engaging units 112 and is configured to drive the ground engaging units 112 to move the machine 100 over the surface 123. The hydraulic power system 119 may be powered by the power source 116 and is configured to provide power to the propulsion system 117, and / or the actuators (e.g., boom actuator 120, stick actuator 130, etc.), and / or the various attachments and components of the machine 100.

[0011] The excavator 102 further includes a boom 118 pivotally mounted on the body 110 and a hydraulic actuator assembly including a boom actuator 120 operable for a user to manipulate the boom 118 by raising and lowering the boom 118 relative to the body 110. The excavator 102 further includes a stick 128 pivotally connected to the boom 118 and a stick actuator 130 connected to the stick 128. The stick actuator 130 is configured to pivot the stick 128 about the boom 118.

[0012] The pin grappler coupler 122 is disposed on an end of a stick 128 and is configured to receive a tool 124, such as a bucket, grapple, hammer, compactor, or another attachment. In the embodiment shown in FIG. 1, the stick 128 is connected to the pin grappler coupler 122 by a first stick pin 132a. The stick actuator 130 is operably connected to the pin grappler coupler 122 by a power link 134 coupled to the second stick pin 132b. The stick actuator 130 is further configured to pivot the pin grappler coupler 122 about the first stick pin 132a.

[0013] The operator's compartment 108 is configured to accommodate control levers, joysticks, push buttons, and other types of control elements commonly known in the art for actuating the operation of the excavator 102, ground engaging unit 112, boom 118, stick 128, and pin grubber coupler 122 and tool 124. The machine 100 has multiple operation modes. The operation modes may include off, normal, and / or hazard detection mode. When in the hazard detection mode, the machine 100 is (a) turned on, and (b) movement of the machine 100 (e.g., rotational movement of the upper carriage 104 / lower carriage 106, translational movement of the entire machine 100 over the surface 123, etc.) is disabled, and / or operation of one or more actuators 126 located on the machine (e.g., hydraulic actuators, electric actuators, mechanical actuators, or the like, such as the boom actuator 120 or stick actuator 130).

[0014] The machine 100 may further include a detection system 136. The detection system 136 may be located on the machine 100 or may be located remotely from the machine 100. The detection system 136 may include one or more sensors 138, one or more output members 140, and a detection system controller 142. The detection system controller 142 is configured to be in operative communication with the one or more sensors 138 and to receive hazard data from such sensors 138. The output members 140 may include, but are not limited to, a visual indication, a log, a horn, a flashing light, a buzzer, and the like. The detection system controller 142 may include a detection system processor 152 and a detection system memory component 148.

[0015] The sensors 138 may be located on the machine 100 or may be located remotely from the machine 100. The hazard data indicates the detection of another machine, a person, an animal, a wall, a barrier, a plant, an object, or the like (each a "hazard"), or the detection of a hazard within a detection distance 144 from the machine 100, or the detection of a hazard in a monitored area 146 around the machine 100.

[0016] The detection system controller 142 may be configured to activate / trigger a hazard detection mode of the machine 100 in response to receiving hazard data from one or more sensors 138. For example, the detection system controller 142 may be configured to generate and send control commands to change the operation mode of the machine 100 from a normal mode to a hazard detection mode based on the received hazard data, and to (a) disable movement of the machine 100 (translation, rotation, etc.) and / or (b) disable movement of one or more actuators 126 (e.g., hydraulic actuators such as the boom actuator 120 or stick actuator 130, electric actuators, mechanical actuators, or the like) disposed on the machine to prevent manipulation / movement of associated components on the machine (e.g., the stick 128, boom 118, tool 124, or the like).

[0017] In an embodiment, the detection system controller 142 may be configured to store the operating mode in the detection system memory component 148 or database and / or transmit the operating mode of the machine 100 to the controller 154 of the maintenance system 150. The maintenance system 150 may be configured to be part of the detection system 136, a module of the detection system 136, or a separate system. The detection system controller 142 may be in operative communication with the output member 140 and configured to activate the output member 140 to issue an audible alarm or display a visual warning, via a display screen, flashing lights, etc., when the machine 100 is in the hazard detection mode or when an operator attempts to operate / move the machine 100 when the machine 100 is in the hazard detection mode. The output member 140 is configured to issue an audible alarm and / or display a visual warning, via a display screen, flashing lights, etc., when activated by the detection system controller 142.

[0018] 2 illustrates an example maintenance system 150 in accordance with the present disclosure. Maintenance system 150 includes a controller 154. Maintenance system 150 may further include switches, buttons, levers, key card sensors, key locks, and the like (collectively, "switches 164") located on machine 100.

[0019] The controller 154 may be in operative communication with a user interface 156 configured to receive input from a user and / or output information to a user. The user interface 156 is configured to transmit authorization data to the controller 154 of the maintenance service system 150 and may be located on the machine 100 (e.g., the operator's station 108) or may be located remotely from the machine 100 (e.g., a mobile phone, tablet, computer, etc.). The authorization data may be information (e.g., a code, etc.) entered by the user into the user interface 156, or the authorization data may be based on information entered by the user into the user interface 156. Alternatively, or additionally, the user interface 156 may be in operative communication with a remote monitoring system 158 (e.g., with a fleet management system, or with a machine dealer system), and the authorization data may be requested from the monitoring system 158 by the user interface 156 and then transmitted by the user interface 156 to the controller 154 upon receipt of the authorization data by the user interface 156 (or the authorization data may be transmitted by the monitoring system 158 itself to the controller 154).

[0020] The controller 154 may be in operative communication with a maintenance tool 160. For example, at times, maintenance or service personnel may connect a portable maintenance tool 160 to the controller 154 while maintaining, troubleshooting, or calibrating the machine 100 at a factory, repair or maintenance shop, dealership, or in the field. Such a maintenance tool 160 may be configured to output information to a user regarding the machine 100, components 162 of the machine 100, and / or one or more systems of the machine 100. The maintenance tool 160 is also configured to transmit authorization data to the controller 154. The authentication data may be information (e.g., a code, etc.) entered into the maintenance tool 160 by a user, or the authentication data may be based on information entered into the maintenance tool 160 by a user, or the authentication data may be programmed or stored in the maintenance tool 160.

[0021] The controller 154 may be in operative communication with a monitoring system 158 located remotely from the machine 100, e.g., a fleet management system configured to monitor the condition of the machine 100. Such monitoring system 158 may be configured to transmit authorization data to the controller 154. The authorization data may be generated automatically by the monitoring system 158 in response to an input or request from a user interface 156 in operative communication with the monitoring system 158, or the authorization data may be received by the monitoring system 158 from a user interface 156 (e.g., a code entered into a computer, a fleet user interface by a user overseeing monitoring of the machine 100 by the monitoring system 158, or the like) and then transmitted to the controller 154, or alternatively may be based on information received by the user interface 156 in operative communication with the monitoring system 158.

[0022] The controller 154 may be in operative communication with a switch 164 disposed on the machine 100. The switch 164 is configured to transmit authorization data (e.g., a code) to the controller 154 when the switch 164 is actuated by a user.

[0023] The controller 154 may be in operative communication with an output member 140 disposed on the machine 100 .

[0024] The controller 154 may include a processor 166 and a memory component 168. The controller 154 is in operative communication with the hydraulic power system 119 and / or the propulsion system 117. In the embodiment shown in FIG. 2, the controller 154 may be in operative communication with a detection system controller 142 of the detection system 136. In other embodiments, the controller 154 of the maintenance system 150 may be part of the detection system 136 or a module / portion of the detection system controller 142.

[0025] Controller 154 may be configured to receive the currently active operating mode of machine 100. In one embodiment, the operating mode may be received from a detection system controller 142 of detection system 136, which is in operative communication with controller 154 of maintenance system 150. In another embodiment, the operating mode may be retrieved by controller 154 from detection system memory component 148 or from another database with which controller 154 is in operative communication.

[0026] The controller 154 is configured to receive authentication data. Such authentication data may be received from a user interface 156, a maintenance tool 160, a monitoring system 158, or a switch 164.

[0027] When the machine 100 is in the hazard detection mode and responds to receiving valid authentication data, the controller 154 is configured to (a) reduce power delivered to the hydraulic power system 119 of the machine 100, and (b) enable movement of the machine 100 at a reduced speed and / or enable operation of one or more actuators 126 at a reduced speed. Reducing the power delivered to the hydraulic power system 119 has the effect of reducing the power output by the hydraulic power system 119 to the propulsion system 117, thereby reducing the translational speed of the machine 100, and also has the effect of reducing the power output to the actuators 126, thereby reducing the speed of operation of the actuators 126.

[0028] In one embodiment, the reduced speed may be less than 1% to 50% of the speed available in normal mode for the machine 100 (normal machine speed) or actuator 126 (normal actuator speed). In another embodiment, the reduced speed may be 10% to 25% of the speed available in normal mode for the machine 100 (normal machine speed) or actuator 126 (normal actuator speed). In a refinement, the controller 154 may be further configured to enable operation of the machine 100 or actuator 126 during an enablement period or until the machine 100 enters an off mode (is turned off) or is restarted.

[0029] The controller 154 may also be further configured to stop or inhibit the display of a visual warning and / or the issuance of an audible alarm / alert by the output member 140 when the machine 100 is moved or when an actuator is operated while the machine is in the hazard detection mode.

[0030] In some embodiments, the controller 154 may be configured to receive a state selection of "maintenance" or "calibration" (in addition to the authentication data). If a state selection of maintenance is received (in addition to the authentication data), the controller may be configured to: (a) reduce power delivered to the hydraulic power system 119 of the machine 100, enable movement of the machine 100 at a reduced speed, and / or enable operation of one or more actuators 126 at a reduced speed, and disable or inhibit display of a visual warning and / or issuance of an audible alarm / alert by the output members 140 when the machine 100 is moved or when an actuator is operated while the machine is in a hazard detection mode. In some embodiments, the controller may transmit information related to the use of the "maintenance" state to the detection system 136 for logging into the detection system memory component 148.

[0031] If a calibration state selection is received (in addition to the authentication data), the controller 154 may be configured to reduce power delivered to the hydraulic power system 119 of the machine 100 and enable movement of the machine 100 at a reduced speed and / or enable operation of one or more actuators 126 at a reduced speed when the machine 100 is moved or when an actuator is operated while the machine 100 is in the hazard detection mode, but not suppress (a) the display of a visual warning and / or (b) the issuance of an audible alarm / alert by the output members 140. Not suppressing or stopping the audible alarm or alert or visual warning may aid in the calibration of the machine 100 or the actuators 126.

[0032] The processor 166 may be a microcontroller, a digital signal processor (DSP), an electronic control module (ECM), an electronic control unit (ECU), a microprocessor, or any other suitable processor 166 known in the art. The processor 166 may execute instructions and generate control signals to reduce power delivered to the hydraulic power system 119, enable movement of the machine 100 at a reduced speed and / or operation of one or more actuators 126 at a reduced speed, or inhibit the output member 140 from displaying a visual warning and / or emitting an audible alarm. Such instructions may be read into or embedded in a computer readable medium, such as a memory component 168, or may be provided external to the processor 166. In alternative embodiments, hardwired circuitry may be used in place of or in combination with software instructions to implement the control methods.

[0033] As used herein, the term "computer-readable medium" refers to any non-transitory medium or combination of media that participates in providing instructions to the processor 166 for execution. Such media may include all computer-readable media, except for transitory propagating signals. Common forms of computer-readable media include, for example, a floppy disk, a flexible disk, a hard disk, a magnetic tape, or any other magnetic medium, a CD-ROM, any other optical medium, or any other computer-readable medium.

[0034] The controller 154 is not limited to one processor 166 and memory component 168. The controller 154 may include several processors 166 and memory components 168. In an embodiment, the processors 166 may be parallel processors having access to a shared memory component 168. In another embodiment, the processor 166 may be part of a distributed computing system in which the processor 166 (and its associated memory component 168) may be located remotely from one or more other processors 166 (and associated memory components 168) that are part of the distributed computing system. The controller 154 may also be configured to retrieve from the memory component 168 the operating mode of the machine 100 or other data necessary for operation as discussed herein.

[0035] Also disclosed is a method of controlling machine 100, where machine 100 has multiple operating modes, the multiple operating modes including a normal mode, a hazard detection mode, and an off mode. The method may include receiving, by controller 154, authentication data after activation of the hazard detection mode, and enabling, by controller 154, movement of machine 100 at a reduced machine speed based on the authentication data, where the reduced machine speed is less than 50% of the normal machine speed available to machine 100 when the operating mode is the normal mode. [Industrial Applicability]

[0036] In general, the foregoing disclosure finds utility in a machine 100 having a detection system 136 or the like that prevents movement of the machine 100 or actuators 126 thereon during maintenance, calibration, or troubleshooting if a sensor 138 associated with the machine 100 detects another machine, a person, an animal, a wall, a barrier, a plant, an object, or the like in proximity to the machine 100. With the teachings of the present disclosure, an operator or technician may move the machine 100 to a desired location or troubleshoot or maintain the machine 100 and / or the actuators 126.

[0037] In operation, the controller 154 may be configured to operate in accordance with a predetermined method 300, for example, as shown in Figure 3. Figure 3 is an exemplary flow chart illustrating sample blocks that may be followed in a method 300 for controlling the machine 100 in a hazard detection mode.

[0038] At block 305 , the currently active operating mode of the machine 100 is received by the controller 154 .

[0039] At block 310, the method 300 includes receiving, by the controller 154, authentication data. The authentication data may be received from the user interface 156, the service tool 160, the monitoring system 158, or the switch 164.

[0040] At block 315 , the method 300 optionally includes receiving, by the controller 154 , a status selection (maintenance or calibration) of the machine 100 .

[0041] In block 320, the method 300 includes, if the currently active operating mode is the hazard detection mode and the controller 154 receives valid authentication data for the machine 100, reducing power delivered by the controller 154 from the power source 116 to the hydraulic power system 119 of the machine 100, and enabling, by the controller 154, movement of the machine 100 (at a reduced speed) and / or operation of one or more actuators 126 (at a reduced speed) in response to and based on the received authentication data. In one embodiment, the reduced speed may be less than 1%-50% of the speed available in normal mode for the machine 100 and / or the actuators 126. In another embodiment, the reduced speed may be 10-25% of the speed available in normal mode for the machine 100 and / or the actuators 126. In a refinement, the enabling may be for the duration of the enabling period or until the machine 100 enters an off mode (is turned off) or is restarted.

[0042] At block 325, the method may optionally further include disabling or inhibiting display of a visual warning and / or issuance of an audible alarm / alert by output member 140 if machine 100 is moved or if an actuator is manipulated while the machine is in the hazard detection mode. In some embodiments, the disabling or inhibiting may be done automatically by controller 154 or may occur only if the user inputs a state selection of the maintenance state at block 315. In some embodiments, block 325 may be omitted if the user inputs a state selection of the calibration state at block 315.

[0043] It may be desirable to perform one or more of the blocks illustrated in FIG. 3 in a different order than the blocks illustrated.

[0044] It will be appreciated from the foregoing that, while only certain embodiments have been described for purposes of illustration, alternatives and modifications will be apparent to those skilled in the art from the above description. These and other alternatives are considered equivalents and are within the spirit and scope of the present disclosure and the appended claims.

Claims

1. A maintenance system (150) for a machine (100) including a plurality of operation modes, the plurality of operation modes including a normal mode and a hazard detection mode, the maintenance system (150) comprising: A control device (154) comprising: receiving acknowledgement data when the machine (100) is in said hazard detection mode; and a controller (154) configured to enable movement of the machine (100) at a reduced machine speed based on the authorization data, the reduced machine speed being less than 50% of a normal machine speed available to the machine (100) when the operating mode is the normal mode; The danger detection mode prevents movement of the machine (100).

2. 2. The maintenance system (150) of claim 1, wherein the authorization data is received from a user interface (156), a monitoring system (158), a maintenance tool (160), or a switch (164) located on the machine (100).

3. 2. The maintenance system (150) of claim 1, wherein the plurality of operating modes further includes an off mode, and movement of the machine (100) in the hazard detection mode is enabled by the controller (154) for an enablement period or until the operating mode changes from the hazard detection mode to the off mode.

4. The hazard detection mode further prevents operation of an actuator (126) located on the machine (100); The control device (154) 2. The maintenance system of claim 1, further configured to enable operation of the actuator at a reduced actuator speed based on the authorization data, the reduced actuator speed being less than 50% of a normal actuator speed available to the actuator when the operating mode is the normal mode.

5. 2. The maintenance system (150) of claim 1, wherein the machine (100) further includes a hydraulic power system (119) operatively connected to a propulsion system (117), and the controller (154) is further configured to reduce electrical power delivered to the hydraulic power system (119) of the machine (100) to enable movement of the machine (100) in the hazard detection mode at the reduced machine speed.

6. the plurality of operation modes further includes an off mode; 2. The maintenance system (150) of claim 1, wherein the control device (154) is further configured to enable movement of the machine (100) at the normal machine speed when the operation mode changes from the hazard detection mode to the off mode and the machine (100) is subsequently restarted.

7. 10. The maintenance system of claim 1, wherein the hazard detection mode is triggered in response to detecting a hazard, the hazard comprising a person, an animal, a wall, a barrier, a plant, an object, or another machine.

8. 2. The maintenance system (150) of claim 1, wherein the controller (154) is further configured to suppress issuance or display of an audible alarm, alert, or visual warning by an output member (140) associated with the machine (100) while the machine (100) is being moved while in the hazard detection mode.

9. A method of controlling a machine (100), the machine (100) having a plurality of operating modes, the plurality of operating modes including a normal mode, a hazard detection mode, and an off mode; receiving, by a control device (154), acknowledgement data after activation of said hazard detection mode; and enabling, by the control device (154), movement of the machine (100) at a reduced machine speed based on the approval data, the reduced machine speed being less than 50% of a normal machine speed available to the machine (100) when the operating mode is the normal mode.

10. The method of claim 9, wherein the authorization data is received from a user interface (156), a monitoring system (158), a maintenance tool (160), or a switch (164).

Images