Industrial machinery with automatic dump control

Abstract

To provide control to alleviate an impact force received by a component in a dump cylinder of an industrial machine by monitoring a position of a piston in a dump cylinder.SOLUTION: A position of a piston is determined by using a sensor in a dump cylinder. The sensor generates an output signal, and provides the output signal to a controller. The controller is configured so as to restrict movement of the dump cylinder during dump operation based on the output signal from the sensor, and to reduce wear of the dump cylinder (for example, by preventing damage generated when the dump cylinder is quickly expanded or retreated, and the inside cylinder component is brought into strong contact with a rod or a cap end).SELECTED DRAWING: Figure 15

Description

[Technical field]

[0001] The embodiments described herein relate to industrial machines, such as shovels or excavators. [Background technology]

[0002] Traditionally, the dumping process (e.g., bucket opening) of a hydraulic excavator is initiated and controlled by the excavator operator using, for example, an analog sensor associated with a foot pedal. However, without knowing the position of the dump cylinder (i.e., the position of the piston within the dump cylinder), the piston can move to a fully extended and / or retracted position at a very high rate of speed. Reaching a fully extended or retracted position at a high rate of speed can lead to component wear and premature component failure.

[0003] The embodiments described herein provide control of a dump operation of an industrial machine by monitoring the position of a piston within a dump cylinder. The position of the piston is determined using a sensor that may be included within the dump cylinder. The sensor generates and provides an output signal to a controller. Based on the output signal from the sensor, the controller is configured to limit the movement and speed of the dump cylinder during the dump operation to reduce wear on the dump cylinder (e.g., by preventing damage that occurs when the dump cylinder extends or retracts rapidly and causes internal cylinder components to come into forceful contact with the rod or cap end). In some embodiments, the dump operation is automated to automatically open and close the bucket door within the full range of motion of the bucket. For example, the position sensor can be calibrated to implement a deceleration region where the dump cylinder piston decelerates and gradually approaches the end of travel position. As a result, impact forces experienced by the internal components of the dump cylinder are reduced, which can improve the operational life of the dump cylinder. Summary of the Invention

[0004] In some embodiments, an industrial machine is provided that includes a bucket, a dump cylinder, a position sensor, and an electronic controller. The bucket has a body and a door, and the industrial machine is configured to operate the bucket to excavate material. The dump cylinder has a piston and is configured to open and close the door. The position sensor is configured to detect a position of the piston in the dump cylinder. The electronic controller includes a processor and a memory and is configured to control the dump cylinder at an initial velocity from a first position toward a second position to move the door. The electronic controller is further configured to receive an output signal from the position sensor and determine a position of the piston based on the output signal. The electronic controller is further configured to reduce a velocity of the dump cylinder from an initial velocity based on the determined position of the piston as the dump cylinder moves from the first position toward the second position.

[0005] In some embodiments, the electronic controller is further configured to determine when the piston reaches a second position based on a further output signal from the position sensor, and to stop the dump cylinder based on determining that the piston has reached the second position.

[0006] In some embodiments, the first position is selected from the group of a fully open target position where the door is open and material in the bucket is discharged, and a fully closed target position where the door is closed and material in the bucket is retained, and the second position is the other of the fully open and fully closed target positions.

[0007] In some embodiments, to reduce the velocity of the dump cylinder from an initial velocity based on the output signal, the electronic controller is configured to reduce the velocity of the dump cylinder according to a function selected from the group of a linear ramp down function, a logarithmic ramp down function, and a quadratic ramp down function.

[0008] In some embodiments, the second position is an end-of-travel position, and the piston further includes a velocity transition point located between the first position and the second position, the velocity transition point being closer to the second position than to the first position. In some of these embodiments, to reduce the velocity of the dump cylinder from an initial velocity based on the output signal, the electronic controller is configured to determine, based on the output signal, that the piston has reached the velocity transition point, and in response, reduce the velocity of the dump cylinder from the initial velocity.

[0009] In some embodiments, the electronic controller is further configured to calibrate the position sensor and thus learn the first position, the second position, and the speed transition points of the dump cylinder.

[0010] In some embodiments, the electronic controller is further configured to control the dump cylinder at an initial return speed from the second position towards the first position to move the door, receive a further output signal from the position sensor, determine a position of the piston based on the further output signal, and reduce the speed of the dump cylinder from the initial return speed as the dump cylinder moves from the second position to the first position based on the position of the piston determined based on the further output signal.

[0011] In some embodiments, at least one selected from the group of the initial velocity and the initial return velocity is a maximum velocity of the dump cylinder.

[0012] In some embodiments, the electronic controller is further configured to receive a signal from the user interface activating the automatic dump control. In some of these embodiments, the electronic controller is further configured to control the dump cylinder at an initial velocity to move from the first position toward the second position in response to receiving the signal activating the automatic dump control.

[0013] In another embodiment, a method for controlling a bucket of an industrial machine is provided. The industrial machine is configured to operate a bucket to excavate material, the bucket having a body and a door. The method includes controlling, by an electronic controller, a dump cylinder at an initial velocity from a first position toward a second position to move the door of the bucket. The dump cylinder has a piston and is configured to open and close the door. The electronic controller further receives an output signal from a position sensor configured to sense a position of the piston in the dump cylinder and determines a position of the piston based on the output signal. As the dump cylinder moves from the first position to the second position, the electronic controller reduces a velocity of the dump cylinder from the initial velocity based on the determined position of the piston.

[0014] In some embodiments of the method, the electronic controller determines when the piston reaches a second position based on a further output signal from the position sensor and stops the dump cylinder based on determining that the piston has reached the second position.

[0015] In some embodiments of the method, the first position is selected from one group of a fully open target position where the door is open and material in the bucket is discharged, and a fully closed target position where the door is closed and material in the bucket is retained, and the second position is the other of the fully open target position and the fully closed target position.

[0016] In some embodiments of the method, to reduce the velocity of the dump cylinder from an initial velocity based on the output signal, the electronic controller reduces the velocity of the dump cylinder according to a function selected from the group of a linear ramp down function, a logarithmic ramp down function, and a quadratic ramp down function.

[0017] In some embodiments of the method, the second position is an end-of-travel position and the piston further includes a velocity transition point located between the first position and the second position, the velocity transition point being closer to the second position than to the first position. In some of these embodiments, to reduce the velocity of the dump cylinder from an initial velocity based on the output signal, the electronic controller determines, based on the output signal, that the piston has reached the velocity transition point and, in response, reduces the velocity of the dump cylinder from the initial velocity.

[0018] In some embodiments, the method further includes calibrating the position sensor thus learning the first position, the second position, and the speed transition point of the dump cylinder.

[0019] In some embodiments of the method, the electronic controller controls the dump cylinder at an initial return speed from the second position towards the first position to move the door, receives a further output signal from the position sensor, determines a position of the piston based on the further output signal, and reduces the speed of the dump cylinder from the initial return speed as the dump cylinder moves from the second position to the first position based on the position of the piston determined based on the further output signal.

[0020] In some embodiments of this method, at least one selected from the group of the initial velocity and the initial return velocity is a maximum velocity of the dump cylinder.

[0021] In some embodiments of the method, the electronic controller receives a signal from the user interface activating an automatic dump control, and controlling the dump cylinder at an initial velocity to move from the first position to the second position is responsive to receiving the signal activating the automatic dump control.

[0022] Other aspects of the embodiments will become apparent by consideration of the detailed description and accompanying drawings. [Brief description of the drawings]

[0023] [Figure 1] FIG. 1 illustrates an industrial machine according to an embodiment described herein. [Diagram 2] FIG. 2 illustrates a control system for an industrial machine according to embodiments described herein. [Diagram 3] FIG. 3 illustrates a bucket and dump cylinder according to embodiments described herein. [Figure 4] FIG. 4 illustrates a dump cylinder in a fully extended position according to embodiments described herein. [Diagram 5] FIG. 5 illustrates a dump cylinder in a fully retracted position according to embodiments described herein. [Figure 6] FIG. 6 illustrates a dump cylinder according to embodiments described herein. [Figure 7] FIG. 7 shows a cross section of the dump cylinder of FIG. [Figure 8] FIG. 8 illustrates a dump cylinder including a sensor according to embodiments described herein. [Figure 9] FIG. 9 shows the sensor of FIG. [Figure 10] FIG. 10 illustrates a dump cylinder speed control graph for a bucket door moving from a fully closed position to a fully open position according to embodiments described herein. [Figure 11] FIG. 11 illustrates a dump cylinder speed control graph for a bucket door moving from a fully open position to a fully closed position according to embodiments described herein. [Figure 12] 12, 13, and 14 are a process for automatically controlling a dump operation of the industrial machine of FIG. 1 according to embodiments described herein. [Figure 13] Same as above. [Figure 14] Same as above. [Figure 15] FIG. 15 is a process for automatically controlling a dump operation of the industrial machine of FIG. 1 according to embodiments described herein. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0024] Before describing the embodiments in detail, it should be understood that the embodiments are not limited in their application to the details of the configuration and arrangement of components set forth in the following description or illustrated in the accompanying drawings. The embodiments can be implemented or carried out in various ways. It should also be understood that the phraseology and terminology used herein are for the purposes of description and should not be regarded as limiting. The words "including," "comprising," or "having" and variations thereof herein are meant to include the items listed thereafter and equivalents thereof as well as additional items. The terms "mounted," "connected," "supported," and "coupled," and variations thereof, are used broadly to encompass both direct and indirect mounting, connecting, supporting, and coupling.

[0025] Further, it should be understood that the embodiments may include hardware, software, and electronic components or modules that, for purposes of explanation, may be shown and described as if the majority of the components were implemented in hardware only. However, those skilled in the art will understand, based on reading this detailed description, that in at least one embodiment, the electronic-based aspects may be implemented in software (e.g., stored in a non-transitory computer-readable medium) that is executable by one or more processing units, such as a microprocessor and / or an application-specific integrated circuit ("ASIC"). Thus, it should be noted that a number of hardware and software-based devices, as well as a number of different structural components, may be utilized to implement the embodiments. For example, a "server," "computing device," "controller," "processor," etc. described herein may include one or more processing units, one or more computer-readable media modules, one or more input / output interfaces, and various connections (such as a system bus) connecting the components.

[0026] Relative terms, such as, for example, "about," "approximately," and "substantially," used in connection with an amount or condition, will be understood by one of skill in the art to include the stated value and have a meaning determined by the context (e.g., the term includes at least the degree of error associated with the precision of the measurement, the tolerance associated with a particular value (e.g., manufacture, assembly, use, etc.)). Such terms are deemed to disclose a range defined by the absolute values ​​of the two endpoints. For example, the phrase "about 2 to about 4" also discloses the range "2 to 4." Relative terms can refer to plus or minus a percentage of the indicated value (e.g., 1%, 5%, 10%, or more).

[0027] Functions described herein as being performed by one component may be performed in a distributed manner by multiple components. Similarly, functions performed by multiple components may be integrated and performed by a single component. Similarly, components described as performing a particular function may also perform additional functions not described herein. For example, a device or structure configured in a particular way is configured in at least that way, but may also be configured in ways not listed.

[0028] Although the embodiments described herein may be applied to, performed on, or used with a variety of industrial machines (e.g., rope shovels, AC machines, DC machines, hydraulic excavators, etc.), the embodiments described herein are described with respect to an electric rope or power shovel, such as the shovel 100 shown in FIG. 1. The shovel 100 includes tracks 105 for propelling the shovel 100 forward and backward and for rotating the shovel 100 (i.e., by varying the speed and / or direction of the left and right tracks relative to each other). The tracks 105 support a base 110 that includes a cab 115. The shovel 100 further includes a swiveling bucket handle 120 and an attachment 125. In this embodiment, the attachment 125 is shown as a bucket. The attachment 125 includes a door 130 for dumping the contents of the attachment 125. The base 110 can swing or swivel relative to the tracks 105 to move the attachment 125 from an excavation location to a dump location. The excavator 100 includes a boom 135 and a hoist cable 140 that can be wound and unwound within the base 110 to raise and lower the attachment 125. The excavator 100 also includes a saddle block 145 and a sheave 150. The tilt or angle of the attachment 125 is controlled using a tilt hydraulic cylinder 155. The door 130 is controlled by a dump hydraulic cylinder, as described in more detail below.

[0029] The excavator 100 uses four main types of motions: forward and reverse, hoist, crowd, and swing. Through these motions, the excavator 100 is configured to operate the bucket 125 to dig material. Forward and reverse refers to moving the entire shovel 100 back and forth using the track 105. Hoist refers to moving the attachment 125 up and down. Crowd refers to extending and retracting the attachment 125. Swing refers to pivoting the shovel 100 about the axis of the base 110. The overall motions of the excavator 100 utilize one or a combination of forward and reverse, hoist, crowd, and swing.

[0030] The excavator 100 includes a control system 200 including a controller 205, as shown in FIG. 2. The controller 205, also referred to as an electronic controller, is electrically and / or communicatively connected to various modules or components of the system 200 or the excavator 100. For example, the illustrated controller 205 is connected to a user interface module 210, a hoist control drive 215, a swing control drive 220, a crowd control drive 225, one or more dump cylinder position sensors 230, and a dump control drive 235. The dump control drive 235 is connected to a dump actuator 240 (e.g., a hydraulic motor / pump), the hoist control drive 215 is connected to a hoist actuator 245 (e.g., a hoist motor), the swing control drive 220 is connected to a swing actuator 250 (e.g., a swing motor), and the crowd control drive 225 is connected to a crowd actuator 255 (e.g., a crowd motor). The controller 205 includes a combination of hardware and software operable to, among other things, control the operation of the system 200, control the operation of the excavator 100, receive input from a user via the user interface 210, and provide information to a user via the user interface 210, etc.

[0031] Controller 205 includes a number of electrical and electronic components that provide power, operational control, and protection to components and modules within controller 205, system 200, and / or excavator 100. For example, controller 205 includes, among other things, a processing unit 260 (e.g., a microprocessor, microcontroller, or another suitable programmable device), a memory 265, an input unit 270, and an output unit 275. Processing unit 260 includes, among other things, a control unit 280, an arithmetic logic unit ("ALU") 285, and a number of registers 290 (shown in FIG. 2 as a group of registers), and is implemented using a known computer architecture (e.g., a modified Harvard architecture, a von Neumann architecture, etc.). Processing unit 260, memory 265, input unit 270, and output unit 275, as well as the various modules or circuits connected to controller 205, are connected by one or more control buses and / or data buses (e.g., a common bus 295). A control bus and / or data bus is generally shown in Figure 2 for purposes of illustration. The use of one or more control buses and / or data buses for interconnecting and communicating between the various modules, circuits, and components will be known to those of skill in the art in view of the embodiments described herein.

[0032] The memory 265 is a non-transitory computer-readable medium, including, for example, a program storage area and a data storage area. The program storage area and the data storage area can include a combination of different types of memory, such as ROM, RAM (DRAM, SDRAM, etc.), EEPROM, flash memory, hard disk, SD card, or other suitable magnetic, optical, physical, or electronic memory devices. The processing unit 260 is connected to the memory 265 and executes software instructions, which can be stored in the RAM of the memory 265 (e.g., during execution), in the ROM of the memory 265 (e.g., typically permanently), or in another memory or another non-transitory computer-readable medium, such as a disk. Software included in the implementation of the system 200 and the controller 205 can be stored in the memory 265 of the controller 205. The software includes, for example, firmware, one or more applications, program data, filters, rules, one or more program modules, and other executable instructions. The controller 205 is configured to retrieve from the memory 265 and execute instructions related to, among other things, the control processes and methods described herein. In other embodiments, controller 205 includes additional, fewer, or different components. For example, while controller 205 is shown as a single unit, in some embodiments controller 205 is comprised of two or more controllers, and logic and processing may be distributed among the multiple controllers. Regardless of how the hardware and software components are combined or divided, they may be located on the same computing device or distributed across different computing devices connected by one or more networks or other suitable communications links.

[0033] The user interface module 210 is used to control and / or monitor the excavator 100. For example, the user interface module 210 is operably coupled to the controller 205 to control the position of the bucket 125, the position of the boom 135, the position of the bucket handle 120, etc. The controller 205 is configured to receive input signals from the user interface module 210. The user interface module 210 includes a combination of digital and analog input or output devices necessary to achieve a desired level of control and monitoring of the excavator 100. For example, the user interface module 210 includes a display (e.g., a primary display, a secondary display, etc.) and input devices such as a touch screen display, a joystick, a plurality of knobs, dials, switches, buttons, pedals, etc. The user interface module 210 can also be configured to display status or data related to the excavator 100 in real time or substantially real time. For example, the user interface module 210 is configured to display measured electrical characteristics of the excavator 100, the status of the excavator 100, the position of the bucket 125, the position of the bucket handle 120, etc. The controller 205 also receives motion command signals from the user interface module 210. The motion command signals include, for example, hoist, lower, extend crowd, retract crowd, swing clockwise, swing counterclockwise, open bucket door, forward left truck, reverse left truck, forward right truck, and reverse right truck. Upon receiving the motion command signals, the controller 205 controls the hoist control drive 215, the swing control drive 220, the crowd control drive 225, and the dump control drive 235 as commanded by the operator.

[0034] In some embodiments, the user interface 210 includes an input (e.g., a button, switch, pedal, etc.) for initiating automatic opening and closing of the door 130 of the bucket 125. For example, the dump cylinder position sensor 230 can be located in one or more dump cylinders associated with the bucket 125. FIG. 3 illustrates a bucket 300 including a door 301, a body 302, and a dump cylinder 305. The bucket 300 is an example of a bucket 125 that can be attached to the excavator 100. The door 301 and the body 302 are coupled at a hinge point 306 such that the door 301 is configured to swing open to allow contents within the body 302 to fall out of the body 302 and close to retain the excavated material inside the body 302. One end of the dump cylinder 305 is connected to a door connection point 307 of the door 301, and the other end of the dump cylinder 305 is connected to a body connection point 308 (see FIGS. 5-6). The dump cylinders 305 extend and retract to open and close the door 301 relative to the body 302. Although only one cylinder is shown in FIG. 3, a similar dump cylinder 305 may be provided on the opposite side of the bucket 300. For example, FIG. 4 shows a pair of dump cylinders 305 in a fully extended position (e.g., corresponding to the bucket door 130 being fully closed). The tilt cylinders 155, first shown in FIG. 1, are also shown in FIG. 4 in an extended state. The tilt cylinders 155 each have a first end coupled to the door 301 and a second end coupled to the bucket handle 120. FIG. 5 shows the dump cylinders 305 in a fully retracted position (e.g., corresponding to the bucket door 130 being fully open). Similarly, the tilt cylinders 155 are also in a retracted position.

[0035] The dump cylinder 305 is shown in more detail in Figure 6. The dump cylinder 305 includes a cylinder portion 311 and a piston 312. The piston 312 includes a first connector 313 configured to be coupled to a body connection point 308 on the body 302. The cylinder portion 311 includes a second connector 314 configured to be coupled to a door connection point 307. Figure 6 also shows the impact areas 315, 320 when the dump cylinder is fully extended or fully retracted.

[0036] Figure 7 shows the same impact areas, labeled 325, 330, respectively, but with dump cylinder 305 shown in cross section. As shown in Figure 7, piston 312 further includes a shaft 331 and a piston head 332 and is configured to translate linearly within cylindrical chamber 333 of cylinder portion 311. Figure 7 shows dump cylinder 305 in a fully retracted state, with piston 312 shown in a right-most position within cylindrical chamber 313. In a fully extended state (e.g., as shown in Figure 5), piston 312 would be in a left-most position within cylindrical chamber 313 in the view of Figure 7.

[0037] 8 and 9, the dump cylinder 305 includes a sensor 335 (e.g., a linear position sensor). The sensor 335 is one example of a dump cylinder position sensor 230 coupled to the controller 205 (see FIG. 2). The sensor 335 provides an output signal to the controller 205 related to the linear position of the piston of the dump cylinder 305. For example, the output signal can be a voltage signal proportional to the amount of linear extension of the sensor 335 caused by linear movement of the piston 312 within the cylindrical chamber 333. For example, the sensor 335 can have a first end connected to the cylinder portion 311 and a second end connected to the piston 312 such that relative movement between the piston 312 and the cylinder portion 311 causes an extension (or retraction, as the case may be) of the sensor 335. Based on the output signal from the sensor 335, the controller 205 is configured to determine, for example, whether the bucket door 130 is fully open, fully closed, or somewhere in between. As an illustration, Figure 8 shows the piston 312 fully retracted within the cylinder portion 111. The piston 312 can be extended from the cylinder portion 111 by moving linearly to the left, as shown by travel path 341, until the piston head 332 reaches the end of the chamber 333. In other embodiments, one or more of a different number, arrangement, and orientation of dump cylinders are provided on the bucket 300.

[0038] FIG. 8 also shows hydraulic circuit ports 336 and 337 of the dump cylinder 305 connected to a hydraulic circuit 338. The hydraulic circuit 338 includes the dump actuator 240, a hydraulic fluid reservoir 339, and one or more controllable valves (not shown) controlled, for example, by the controller 205. In an exemplary operation, when hydraulic fluid is pumped into port 337, the piston 312 extends out of the cylinder portion 311 (i.e., to the left in FIG. 8). As the piston 312 extends, the piston head 332 pushes hydraulic fluid in the chamber 333 out of the port 336. Conversely, when hydraulic fluid is pumped into port 336, the piston 312 retracts into the cylinder portion 311 (i.e., to the right in FIG. 8) and the piston head 332 pushes hydraulic fluid out of the chamber 333 through the port 337. In some embodiments, the dump actuator 240 operates as a hydraulic pump that controls the flow of hydraulic fluid into and out of the ports 336, 337. In some embodiments, other hydraulic circuit arrangements are used to control the extension and retraction of the dump cylinder 305.

[0039] When the bucket door 130 is fully closed, and the operator of the excavator 100 activates the automatic control of the dump operation (e.g., by pressing an activation button), the controller 205 controls or has the dump control drive 235 control to drive the dump actuator 240 to the fully open position at an initial speed (e.g., maximum speed, etc.). In some embodiments, the dump actuator 240 is a hydraulic actuator. As the piston 312 of the dump cylinder 305 approaches the fully open position, the speed of the piston 312 can be ramped down by the controller 205 to reduce the shock load experienced by the dump cylinder 305 when it reaches the fully open position. Similarly, when the bucket door 130 is fully open, and the operator of the excavator 100 activates the automatic control of the dump operation (e.g., by pressing an activation button), the controller 205 controls or has the dump control drive 235 control to drive the dump actuator 240 to the fully closed position at an initial speed (e.g., maximum speed, etc.). As the piston 312 of the dump cylinder 305 approaches the fully closed position, the velocity of the piston 312 may be ramped down by the controller 205 to reduce the shock loads experienced by the dump cylinder 305 when the fully closed position is reached. In some embodiments, the operator may deactivate the automatic control of the dump operation or override the automatic dump control at any time (e.g., press the activation button again) by manipulating another input on the user interface 210 (e.g., foot pedal, thumb wheel, etc.). In some embodiments, the automatic dump control is implemented using a conventional dump control (e.g., foot pedal dump control). In such embodiments, the operator may activate the automatic dump control, but may use a conventional manual dump control if the operator wishes to regulate the flow of material from the bucket 125.

[0040] FIG. 10 illustrates a dump cylinder speed control graph 400 as the bucket door 130 moves from a fully closed position to a fully open position. The graph 400 includes a fully closed target position 405, a first maximum speed transition point 410, a second maximum speed transition point 415, a fully open target position 420, a maximum speed portion 425, and a ramp down speed portion 430. The second maximum speed transition point 415 corresponds to the point at which the controller 205 begins to decelerate the piston of the dump cylinder 305 as it approaches the fully open target position 420. Thus, the second maximum speed transition point 415 is closer to the fully open target position 420 than the fully closed target position 405. At the second maximum speed transition point 415, the speed of the piston in the dump cylinder 305 transitions from the maximum speed portion 425 to the ramp down speed portion 430. In some embodiments, the fully open target position 420 is the point at which the controller 205 determines that the bucket door 130 is in a fully open position. FIG. 10 illustrates a linear ramp-down portion 430. In some embodiments, a logarithmic, quadratic, or another function can be used to control the piston's velocity ramp-down (e.g., a non-linear ramp-down portion). Although the graph 400 of FIG. 10 illustrates that the velocity of the piston in the dump cylinder 305 operates at a maximum velocity during the maximum velocity portion 425, in some embodiments, the velocity of the piston 312 in the maximum velocity portion 425 (initial velocity) is the maximum operating velocity of the dump cylinder (e.g., 75%, 80%, or 90% of maximum velocity). Regardless of when the piston reaches the second maximum velocity transition point 415, the velocity of the piston decreases from the initial velocity.

[0041] FIG. 11 illustrates a dump cylinder speed control graph 400 as the bucket door 130 moves from a fully closed position to a fully open position. The graph 400 includes a fully closed target position 405, a first maximum speed transition point 410, a second maximum speed transition point 415, a fully open target position 420, a maximum speed portion 425, and a ramp down speed portion 435. The first maximum speed transition point 410 corresponds to the point at which the controller 205 begins to decelerate the piston of the dump cylinder 305 as the fully closed target position 405 approaches. Thus, the first maximum speed transition point 410 is closer to the fully closed target position 405 than the fully open target position 420. At the first maximum speed transition point 410, the speed of the piston in the dump cylinder 305 transitions from the maximum speed portion 425 to the ramp down speed portion 435. In some embodiments, the fully closed target position 405 is the point at which the controller 205 determines that the bucket door 130 is in a fully closed position. FIG. 11 illustrates a linear ramp-down portion 435. In some embodiments, a logarithmic, quadratic, or another function can be used to control the piston's velocity ramp-down (e.g., a non-linear ramp-down portion). Although the graph 400 of FIG. 11 illustrates that the velocity of the piston in the dump cylinder 305 operates at a maximum velocity during the maximum velocity portion 425, in some embodiments, the velocity of the piston 425 during the maximum velocity portion 425 (initial velocity) is the maximum operating velocity of the dump cylinder (e.g., 75%, 80%, or 90% of maximum velocity). Regardless of when the piston reaches the first maximum velocity transition point 410, the velocity of the piston decreases from the initial velocity.

[0042] In some embodiments, the calibration of the dump cylinder position sensor 230 can be automated. For example, the user interface 210 can be configured to receive an input (e.g., a button press) associated with starting a calibration mode of the dump cylinder position sensor 230. After entering the calibration mode, the user interface 210 can be configured to receive an input (e.g., an auto dump button press) associated with starting a calibration process. In some embodiments, if auto dump is not active, the calibration process ends. During the calibration process, the controller 205 slowly applies a bucket closure reference to the dump control drive 235 (in other words, sends a control signal to control the door 301 to close slowly). When the controller 205 determines (e.g., using the dump cylinder position sensor 230) that the dump cylinder 305 has stopped moving, the controller 205 stores in the memory 265 a fully closed value of the output signal from the dump cylinder position sensor 230. The controller 205 can then slowly apply the bucket open reference to the dump control drive 235 (in other words, send a control signal to control the door 301 to open slowly). When the controller 205 determines (e.g., using the dump cylinder position sensor 230) that the dump cylinder 305 has stopped moving, the controller 205 stores the fully open value of the output signal from the dump cylinder position sensor 230 in the memory 265. In some embodiments, the fully closed target position 405, the first maximum speed transition point 410, the second maximum speed transition point 415, the fully open target position 420, the maximum speed portion 425, the ramp down speed portion 430, and the ramp down speed portion 435 have predetermined values ​​stored in the memory 265 (e.g., for the fully open and fully closed positions). Once the calibration process is complete, the controller 205 applies the values ​​of the fully closed target position 405, the first maximum speed transition point 410, the second maximum speed transition point 415, the fully open target position 420, the maximum speed portion 425, the ramp down speed portion 430, and the ramp down speed portion 435 (i.e., based on the calibrated fully open position and the calibrated fully closed position) to the operational evolution of the dump cylinder 305.For example, these values ​​may be used in processes 500 and 700 described below. Thus, through the calibration process, among other things, the controller is configured to learn the full open target position 420, the full closed target position 405, and the speed transition points 410 and 415 of the dump cylinder.

[0043] 12-14 show a process 500 for automatically controlling the dumping operation of the bucket 125 of the excavator 100. In step 505, the controller 205 determines whether the position of the bucket 125 is fully closed. The controller 205 determines that the position of the bucket 125 is fully closed if the extension of the dump cylinder is equal to or greater than the extension of the dump cylinder at the fully closed target position 405. If the controller 205 determines that the position of the dump cylinder is equal to or greater than the fully closed target position 405, the controller 205 determines that the bucket 125 is fully closed (step 510) and the process 500 proceeds to control section B shown and described with respect to FIG. 13. In step 505, if the position of the dump cylinder is less than the fully closed target position 405, the controller 205 determines whether the position of the bucket is fully open (step 515). The controller 205 determines that the position of the bucket 125 is fully open if the extension of the dump cylinder is equal to or less than the extension of the dump cylinder at the fully open target position 420. If the controller 205 determines that the position of the dump cylinder is less than or equal to the full open target position 420, the controller 205 determines that the bucket 125 is fully open (step 520) and the process 500 proceeds to control section C shown and described with respect to FIG. 14. If the position of the dump cylinder is greater than the full open target position 420 at step 515, the controller 205 determines whether a user input command (e.g., actuated by an operator activating a foot pedal, activating a thumb wheel, etc.) has been received by the controller 205 (step 525). If the controller 205 has not received a user input command, the process 500 waits to receive a user input command at step 525. After a user input command is received at step 525, manual operator control is initiated (step 530) and the process 500 returns to step 505. For example, as described above, at step 530, user input may be received by the controller 205 via the user interface module 210.In response to this user input, the controller 205 is configured to control the position of the bucket 125, the position of the boom 135, the position of the bucket handle 120, etc. For example, the user input may include one or more of the following commands: hoist up, hoist down, crowd extend, crowd retract, swing clockwise, swing counterclockwise, open bucket door, left truck forward, left truck reverse, right truck forward, and right truck reverse.

[0044] 13 and control section B of process 500, the controller 205 determines whether a signal to activate the auto-dump control has been received (e.g., an operator presses an activation button on the user interface 210) (step 535). If the controller 205 does not receive a signal to activate the auto-dump control, the controller 205 determines whether an operator has provided a user input command (e.g., activate a foot pedal or activate a thumb wheel on the user interface 210) (step 540). If the controller 205 does not receive a user input command, the process 500 returns to step 535 to determine whether a signal to activate the auto-dump control has been received. If a user input command is received in step 540, manual operator control is initiated (step 545) and the process 500 returns to control section A shown and described with respect to FIG. 12. The manual operator control in step 545 is similar to the manual operator control in step 530 described above.

[0045] If, at step 535, the controller 205 receives a signal to activate the automatic dump control, the controller 205 initiates the automatic dump control to open the bucket 125 (step 550). The automatic dump control to open the bucket 125 corresponds, for example, to the dump cylinder speed control graph 400 shown and described with respect to FIG. 10. In other words, to implement the automatic dump control to open the door 301, in at least some embodiments, the controller 205 controls the dump cylinder 305 in accordance with the dump cylinder speed control graph 400 shown and described with respect to FIG.

[0046] If during automatic opening of the bucket 125, the controller 205 receives a user input command (e.g., foot pedal activation, thumb wheel activation, etc.) (step 555), the controller 205 terminates automatic opening of the bucket 125 and initiates manual operator control (step 560). The manual operator control in step 560 is similar to the manual operator control in step 530. The process 500 then returns to control section A shown and described with respect to FIG. 12. If a user input command is not received in step 555, the controller 205 determines whether a signal to deactivate the automatic dump control has been received (e.g., the operator presses the activation button again) (step 565). If a signal to deactivate the automatic dump control is received in step 565, the movement of the dump cylinder 305 is stopped (step 570) and the process 500 returns to control section A shown and described with respect to FIG. 12. If no signal is received to deactivate the automatic dump control at step 565, the controller 205 determines whether the bucket 125 is fully open (step 575). If the controller 205 determines that the bucket 125 is fully open, the motion of the dump cylinder 305 is stopped (step 580) and the process 500 returns to control section A shown and described with respect to FIG. 12. As described above with respect to steps 515 and 520 of FIG. 12, the controller 205 is configured to determine that the bucket 125 is fully open in response to (i) receiving an output signal from the dump cylinder position sensor 230, and (ii) determining that the dump cylinder piston position indicated by the output signal is less than the fully open target position 420. If the bucket 125 is not fully open at step 575, the process 500 returns to step 550 where the controller 205 continues to execute the automatic dump control.

[0047] 14 and control section C of process 500, the controller 205 determines whether a signal to activate the auto-dump control has been received (e.g., an operator presses an activation button on the user interface 210) (step 585). If the controller 205 does not receive a signal to activate the auto-dump control, the controller 205 determines whether an operator has provided a user input command (e.g., activate a foot pedal or activate a thumb wheel on the user interface 210) (step 590). If the controller 205 does not receive a user input command, the process 500 returns to step 585 to determine whether a signal to activate the auto-dump control has been received. If a user input command is received in step 590, manual operator control is initiated (step 595) and the process 500 returns to control section A shown and described with respect to FIG. 12. The manual operator control in step 595 is similar to the manual operator control in step 530 described above.

[0048] If, at step 585, the controller 205 receives a signal to activate the automatic dump control, the controller 205 initiates the automatic dump control to close the bucket 125 (step 600). The automatic dump control for closing the bucket 125 corresponds, for example, to the dump cylinder speed control graph 400 shown and described with respect to FIG. 11. That is, to implement the automatic dump control for closing the door 301, in at least some embodiments, the controller 205 controls the dump cylinder 305 in accordance with the dump cylinder speed control graph 400 shown and described with respect to FIG.

[0049] If the controller 205 receives a user input command (e.g., foot pedal activation, thumb wheel activation, etc.) during automatic closure of the bucket 125 (step 605), the controller 205 terminates automatic closure of the bucket 125 and initiates manual operator control (step 610). The manual operator control in step 310 is similar to the manual operator control in step 530. The process 500 then returns to control section A shown and described with respect to FIG. 12. If a user input command is not received in step 605, the controller 205 determines whether a signal to deactivate the automatic dump control has been received (e.g., the operator presses the activation button again) (step 615). If a signal to deactivate the automatic dump control is received in step 615, the movement of the dump cylinder 305 is stopped (step 620) and the process 500 returns to control section A shown and described with respect to FIG. 12. If no signal is received to deactivate the automatic dump control at step 615, the controller 205 determines whether the bucket 125 is fully closed (step 625). If the controller 205 determines that the bucket 125 is fully closed, the motion of the dump cylinder 305 is stopped (step 630) and the process 500 returns to control section A shown and described with respect to FIG. 12. As described above with respect to steps 505 and 510 of FIG. 12, the controller 205 is configured to determine that the bucket 125 is fully closed in response to (i) receiving an output signal from the dump cylinder position sensor 230, and (ii) determining that the dump cylinder piston position indicated by the output signal is greater than the fully closed target position 405. If, at step 625, the bucket 125 is not fully closed, the process 500 returns to step 600 and the controller 205 continues to execute the automatic dump control.

[0050] FIG. 15 illustrates a process 700 for automatically controlling a dump operation of the bucket 125 of the excavator 100. In step 710, an electronic controller, such as the controller 205, controls the dump cylinder 305 at an initial speed to move the door 301 from a first position to a second position. For example, in response to detecting a request to automatically open the door 301 (e.g., see step 550) or to automatically close the door 301 (e.g., see step 600), the controller 205 controls the dump actuator 240 to move the piston 312 of the dump cylinder 305 at an initial speed. This control of the dump cylinder 305 at an initial speed is illustrated, for example, in the maximum speed portion 425 of the graph 400 of FIGS. 10 and 11. The initial speed may be a maximum speed or another initial speed. The first position may be, for example, a fully closed position of the door 301 (e.g., below the fully closed target position 405 in FIGS. 10 and 11) or may be a fully open position of the door 301 (e.g., above the fully open target position 420 in FIGS. 10 and 11).

[0051] In step 720, the controller 205 receives an output signal from the position sensor 230. For example, as discussed above, the position sensor 230 (an example of which is shown in FIG. 9 as position sensor 335) may output a voltage signal having a voltage proportional to the position of the piston 312 within the dump cylinder 305. The position of the piston 312 within the dump cylinder 305 may correspond to the amount of extension of the piston 312 from the cylinder portion 311.

[0052] In step 730, the controller 205 determines the position of the piston 312 based on the output signal from the position sensor 230. For example, the controller 205 may determine a voltage level of the output signal from the position sensor 230 and convert the voltage signal to a position value (e.g., using a look-up table or a conversion equation). The position value may be, for example, a numerical value indicative of the extension of the piston 312 from the cylinder portion 311. With reference to the graph 400 of FIGS. 10 and 11, the numerical value indicative of the extension of the piston 312 may be represented along the x-axis of the graph 400. Although the fully closed position is shown as a smaller value than the fully open position along the x-axis of the graphs of FIGS. 10 and 11, in some embodiments the reference system is reversed such that the fully closed position is a larger value than the fully open position.

[0053] In step 740, as the dump cylinder 305 moves the door 301 from the first position to the second position, the controller 205 reduces the velocity of the dump cylinder 305 from an initial velocity based on the determined position of the piston. For example, as the dump cylinder 305 is controlled to move the door 301 from a first position (e.g., a fully closed position) toward a second position (e.g., a fully open position), the controller 205 may continuously receive a signal from the position sensor 230 and determine a position of the piston 312. The controller 205 may continuously compare the determined position to the velocity transition point 410 (when closing) or the velocity transition point 415 (when opening). Then, when the controller 205 determines, based on the output signal from the position sensor 230, that the piston 312 has reached the corresponding velocity transition point 410 or 415, the controller reduces the velocity of the dump cylinder from the initial velocity. As described above, the controller 205 may reduce the velocity of the dump cylinder 305 according to a function selected from the group of a linear ramp-down function (see FIGS. 10 and 11), a logarithmic ramp-down function, and a quadratic ramp-down function.

[0054] In some embodiments, the controller 205 may further continue to monitor the signal from the position sensor 230 and determine when the piston 312 reaches a second position (e.g., the fully open target position 420 or the fully closed target position 405) based on a further output signal from the position sensor. In response, the controller 205 may stop the dump cylinder 305 based on determining that the piston 312 has reached the second position. For example, the controller 205 may stop sending control signals to the dump actuator 240 (e.g., via the dump control drive 235) to stop driving hydraulic fluid in the dump cylinder 305.

[0055] In some embodiments, as described above, the controller 205 can further calibrate the position sensor 230 to thereby learn the first position, second position, and speed transition points of the dump cylinder.

[0056] In some embodiments, after the door reaches the second position and stops, the controller 205 can control the dump cylinder 305 to return to the first position using a process similar to process 700. For example, if the second position is the fully open target position 420 and the first position is the fully closed target position 405 (i.e., process steps 710-740 are used to open the door 301), the controller 205 can receive a signal to automatically close the door 301 after the door 301 is fully opened (e.g., see step 600 of FIG. 14). In response, the controller 205 controls the dump cylinder 305 at an initial return speed to move the door 301 from the second position to the first position, similar to step 710. The controller 205 then receives a further output signal from the position sensor 230 and determines the position of the piston 312 based on the further output signal, similar to steps 720 and 730. Next, similar to step 740, as the dump cylinder 305 moves the door 301 from the second position to the first position, the controller 205 reduces the velocity of the dump cylinder 305 from the initial return velocity based on the position of the piston 312 determined based on the further output signal. The initial return velocity may be the same velocity (albeit in the opposite direction) as the initial velocity, or may be another velocity. The initial return velocity may be the maximum velocity of the dump cylinder 305, or may be another velocity. The controller may determine to reduce the velocity of the dump cylinder 305 based on determining from the further output signal that the piston 312 has reached a velocity transition point 410 (when closing the door 301) or 415 (when opening the door 301).

[0057] As described with respect to Figures 13 and 14, during the course of an auto-close or auto-open operation, the controller 205 may receive a user input command indicating manual operator control (steps 555 and 605) or may receive a signal to deactivate the automatic dump control (steps 565 and 615). Similarly, in some embodiments, during process 700 of Figure 15, the controller 205 may receive a user input command indicating manual operator control or a signal to deactivate the automatic dump control. In response to receiving a user input command indicating manual operator control or a signal to deactivate the automatic dump control, the controller 205 may exit process 700 and initiate manual operator control or stop movement of the dump cylinder 305.

[0058] Although processes 500 and 700 have been described as a series of sequentially performed steps performed in a particular order, in some embodiments one or more steps are performed in parallel, or at least partially in parallel, or in a different order than described.

[0059] Thus, the embodiments described herein provide, among other things, an industrial machine that includes an automatic dump control.

Claims

1. An industrial machine, a bucket having a body and a door, the industrial machine being configured to operate the bucket to excavate material; a dump cylinder having a piston and configured to open and close the door; a position sensor configured to sense a position of the piston within the dump cylinder; An electronic controller including a processor and a memory, controlling the dump cylinder from a first position toward a second position at an initial velocity to move the door; receiving an output signal from the position sensor; determining a position of the piston based on the output signal; and an electronic controller configured to reduce a velocity of the dump cylinder from the initial velocity based on the determined position of the piston as the dump cylinder moves from the first position to the second position.

2. The electronic controller comprises: determining when the piston reaches the second position based on a further output signal from the position sensor; The industrial machine of claim 1 , further configured to stop the dump cylinder based on determining that the piston has reached the second position.

3. the first position is selected from the group of a fully open target position, where the door is open and material in the bucket is discharged, and a fully closed target position, where the door is closed and material in the bucket is retained; The industrial machine according to claim 1 , wherein the second position is the other of the fully open target position and the fully closed target position.

4. 2. The industrial machine of claim 1, wherein to reduce the velocity of the dump cylinder from the initial velocity based on the output signal, the electronic controller is configured to reduce the velocity of the dump cylinder according to a function selected from the group of a linear ramp down function, a logarithmic ramp down function, and a quadratic ramp down function.

5. the second position is an end-of-travel position, the piston further includes a speed transition point located between the first position and the second position, the speed transition point being closer to the second position than to the first position; to reduce a velocity of the dump cylinder from the initial velocity based on the output signal, the electronic controller The industrial machine of claim 1 , configured to determine when the piston has reached the velocity transition point based on the output signal, and in response thereto, to reduce the velocity of the dump cylinder from the initial velocity.

6. The electronic controller comprises:

6. The industrial machine of claim 5, further configured to calibrate the position sensor and thus learn the first position, the second position, and the speed transition point of the dump cylinder.

7. The electronic controller comprises: controlling the dump cylinder at an initial return velocity from the second position toward the first position to move the door; receiving a further output signal from said position sensor; determining a position of the piston based on the further output signal; 2. The industrial machine of claim 1, further configured to reduce a velocity of the dump cylinder from the initial return velocity when the dump cylinder moves from the second position to the first position based on a position of the piston determined based on the further output signal.

8. 8. The industrial machine of claim 7, wherein at least one selected from the group of the initial speed and the initial return speed is a maximum speed of the dump cylinder.

9. The electronic controller comprises: further configured to receive a signal from the user interface to activate the auto-dump control; 2. The industrial machine of claim 1, wherein the electronic controller is further configured to control the dump cylinder at the initial velocity to move from the first position toward the second position in response to receiving the signal activating the automatic dump control.

10. 1. A method of controlling a bucket of an industrial machine configured to operate the bucket to excavate material, the bucket having a body and a door, the method comprising: controlling, with an electronic controller, a dump cylinder from a first position toward a second position at an initial velocity to move the door of the bucket, the dump cylinder having a piston and configured to open and close the door; receiving, by the electronic controller, an output signal from a position sensor configured to sense a position of the piston within the dump cylinder; determining, with the electronic controller, a position of the piston based on the output signal; and reducing, by the electronic controller, a velocity of the dump cylinder from the initial velocity based on the determined position of the piston as the dump cylinder moves from the first position to the second position.

11. determining, by the electronic controller, when the piston reaches the second position based on a further output signal from the position sensor; The method of claim 10 , further comprising: stopping the dump cylinder based on determining that the piston has reached the second position.

12. the first position is selected from the group of a fully open target position, where the door is open and material in the bucket is discharged, and a fully closed target position, where the door is closed and material in the bucket is retained; The method of claim 10 , wherein the second position is the other of the fully open target position and the fully closed target position.

13. 11. The method of claim 10, wherein to reduce the velocity of the dump cylinder from the initial velocity based on the output signal, the electronic controller reduces the velocity of the dump cylinder according to a function selected from the group of a linear ramp down function, a logarithmic ramp down function, and a quadratic ramp down function.

14. the second position is an end-of-travel position, the piston further includes a speed transition point located between the first position and the second position, the speed transition point being closer to the second position than to the first position; to reduce a velocity of the dump cylinder from the initial velocity based on the output signal, the electronic controller 11. The method of claim 10, further comprising determining that the piston has reached the velocity transition point based on the output signal, and in response thereto, decreasing the velocity of the dump cylinder from the initial velocity.

15. 15. The method of claim 14, further comprising calibrating the position sensor thus learning the first position, the second position, and the speed transition point of the dump cylinder.

16. controlling, by the electronic controller, the dump cylinder from the second position toward the first position at an initial return speed to move the door; receiving, by the electronic controller, a further output signal from the position sensor; determining, by the electronic controller, a position of the piston based on the further output signal; 11. The method of claim 10, further comprising: as the dump cylinder moves from the second position to the first position, slowing down the velocity of the dump cylinder from the initial return velocity based on a position of the piston determined based on the further output signal by the electronic controller.

17. 17. The method of claim 16, wherein at least one selected from the group of the initial velocity and the initial return velocity is a maximum velocity of the dump cylinder.

18. further comprising receiving, by the electronic controller, a signal from a user interface to activate an auto-dump control; 11. The method of claim 10, wherein controlling, by the electronic controller, the dump cylinder at the initial velocity to move from the first position to the second position is in response to receiving the signal activating the automatic dump control.

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