Work system
Patent Information
- Application Number
- PCT/JP2024/029462
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-09-05
- Filing Date
- 2024-08-20
- Publication Date
- 2025-03-13
Smart Images

Figure JP2024029462_13032025_PF_FP_ABST
Abstract
Description
Work System
[0001] The present invention relates to a work system.
[0002] Patent Document 1 discloses an automatically operated excavator that determines the deviation between taught position data and current position data based on current distance data.
[0003] On the other hand, in an automatically operated work machine, if there is a deviation in the detection value of a sensor that detects the attitude of an attachment or the like, the operation of the work machine will deviate from the target operation.
[0004] Japanese Patent Application Publication No. 10-183671
[0005] An object of the present invention is to provide a work system that enables detected values relating to the attitude of a detection object to be monitored.
[0006] The present invention provides a work system including a lower traveling body, an upper revolving body, a boom, an arm, a tip attachment, an attitude detector, an information acquisition device, an attitude calculation unit, and a deviation calculation unit. The upper revolving body is rotatably mounted on the lower traveling body. The boom is connected to the upper revolving body so as to be rotatable in the vertical direction. The arm is connected to the boom so as to be rotatable in the vertical direction. The tip attachment is rotatably connected to the arm. The attitude detector detects the attitude of at least one detection object, and the at least one detection object is selected from the lower traveling body, the upper revolving body, the boom, the arm, and the tip attachment. The information acquisition device acquires three-dimensional information of the detection object. The attitude calculation unit calculates the attitude of the detection object based on the three-dimensional information acquired by the information acquisition device. The deviation calculation unit calculates the deviation between the attitude detected by the attitude detector and the attitude calculated by the attitude calculation unit.
[0007] FIG. 1 is a side view showing a work system according to a first embodiment of the present invention. FIG. 2 is a block diagram showing some of the components of the work system. FIG. 3 is a side view of an attachment according to the first embodiment, showing an example of the arrangement of marks affixed to the attachment. FIG. 4 is a side view of an attachment according to the first embodiment, showing a modified example of the arrangement of marks. FIG. 5 is a flowchart showing processing executed in the first embodiment. FIG. 6 is a side view of an attachment according to a second embodiment of the present invention. FIG. 7 is a flowchart showing processing executed in the second embodiment. FIG. 8 is a diagram showing a three-dimensional model of an attachment according to a third embodiment of the present invention. FIG. 9 is a flowchart showing processing executed in the third embodiment. FIG. 10 is a plan view showing the attitude of an upper rotating body of a work machine according to a fourth embodiment of the present invention. FIG. 11 is a flowchart showing processing executed in the fourth embodiment. FIG. 12 is a perspective view of a work machine according to a fifth embodiment of the present invention. FIG. 13 is a flowchart showing processing executed in the fifth embodiment.
[0008] Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.
[0009] Figure 1 shows a work system 1 according to a first embodiment of the present invention. The work system 1 includes a work machine 20, an imaging device 5, and a plurality of sensors 50. The work machine 20 illustrated in Figure 1 is a hydraulic excavator. The work machine 20 includes a machine body 24 including a lower traveling body 21 and an upper rotating body 22, an attachment 30, and a plurality of cylinders 40.
[0010] The lower traveling body 21 is a part that performs traveling operations and includes, for example, a pair of left and right crawlers. The upper rotating body 22 is mounted on the lower traveling body 21 so as to be rotatable via a rotating device 25. The upper rotating body 22 includes a cab (operator's compartment) 23, and the cab 23 forms the front part of the upper rotating body 22.
[0011] The attachment 30 is attached to the upper rotating body 22 so as to be rotatable in the vertical direction. The attachment 30 includes a boom 31, an arm 32, and a bucket 33. The boom 31 is connected to the upper rotating body 22 so as to be rotatable (raised and lowered) in the vertical direction. The arm 32 is connected to the boom 31 so as to be rotatable in the vertical direction. The bucket 33 is an example of a tip attachment that constitutes the tip of the attachment 30. The bucket 33 is connected to the arm 32 so as to be rotatable in the front-rear direction of the upper rotating body 22. The bucket 33 is a working member for performing work such as excavating, leveling, and scooping earth and sand.
[0012] The end attachment is not limited to the bucket 33. The end attachment may be a lifting magnet that holds iron scraps or the like, or may be another working member.
[0013] The plurality of cylinders 40 are arranged to hydraulically move the attachment 30. Each of the plurality of cylinders 40 is an extendable hydraulic cylinder. Each of the plurality of cylinders 40 may be an electric cylinder.
[0014] The plurality of cylinders 40 include a boom cylinder 41 , an arm cylinder 42 , and a bucket cylinder 43 .
[0015] The boom cylinder 41 performs the extension and contraction operation to rotate the boom 31 relative to the upper rotating body 22. The boom cylinder 41 has a base end portion rotatably connected to the upper rotating body 22 and a tip end portion on the opposite side thereof, and the tip end portion is rotatably connected to the boom 31.
[0016] The arm cylinder 42 rotates the arm 32 relative to the boom 31 by performing the extension and retraction operation. The arm cylinder 42 has a base end portion rotatably connected to the boom 31 and a tip end portion on the opposite side thereof, and the tip end portion is rotatably connected to the arm 32.
[0017] The bucket cylinder 43 rotates the bucket 33 relative to the arm 32 by performing the extension and retraction operation. The bucket cylinder 43 has a base end portion rotatably connected to the arm 32 and a tip end portion on the opposite side. The tip end portion is rotatably connected to a link member 34, and the link member 34 is rotatably connected to the bucket 33.
[0018] The plurality of sensors 50 constitute a posture detector that detects the posture of a detection target. The detection target is selected from the lower traveling body 21, the upper rotating body 22, the boom 31, the arm 32, and the bucket 33. The detection targets according to this embodiment are the boom 31, the arm 32, and the bucket 33.
[0019] The plurality of sensors 50 include a boom tilt angle sensor 51 , an arm tilt angle sensor 52 , a bucket tilt angle sensor 53 , a swing angle sensor 54 , and a tilt angle sensor 55 .
[0020] The boom tilt angle sensor 51 is attached to the boom 31 and detects the attitude of the boom 31. Specifically, the boom tilt angle sensor 51 acquires the tilt angle of the boom 31 with respect to the horizon (horizontal plane). The boom tilt angle sensor 51 is, for example, an inclination sensor such as an acceleration sensor. Alternatively, the boom tilt angle sensor 51 may be a rotation angle sensor that detects the rotation angle of a boom foot pin at the base end of the boom 31, or may be a stroke sensor that detects the stroke of the boom cylinder 41.
[0021] The arm inclination angle sensor 52 is attached to the arm 32 and detects the posture of the arm 32. Specifically, the arm inclination angle sensor 52 acquires the inclination angle of the arm 32 with respect to the horizon (horizontal plane). The arm inclination angle sensor 52 is, for example, an inclination sensor such as an acceleration sensor. The arm inclination angle sensor 52 may alternatively be a rotation angle sensor that detects the rotation angle of an arm connecting pin at the base end of the arm 32, or may be a stroke sensor that detects the stroke of the arm cylinder 42.
[0022] The bucket inclination angle sensor 53 is attached to the link member 34 and detects the attitude of the bucket 33. Specifically, the bucket inclination angle sensor 53 acquires the inclination angle of the bucket 33 with respect to the horizon (horizontal plane). The bucket inclination angle sensor 53 is, for example, an inclination sensor such as an acceleration sensor. The bucket inclination angle sensor 53 may alternatively be a rotation angle sensor that detects the rotation angle of a bucket connecting pin at the base end of the bucket 33, or may be a stroke sensor that detects the stroke of the bucket cylinder 43.
[0023] The swing angle sensor 54 detects the swing angle of the upper swing body 22 with respect to the lower traveling body 21. The swing angle sensor 54 is, for example, an encoder, a resolver, or a gyro sensor. In this embodiment, the swing angle of the upper swing body 22 is 0° when the forward direction of the upper swing body 22 coincides with the forward direction of the lower traveling body 21.
[0024] The inclination angle sensor 55 is attached to, for example, the upper rotating body 22 and detects the inclination angle of the lower traveling body 21 with respect to a horizontal plane. The inclination angle sensor 55 may be, for example, an inclination sensor such as an acceleration sensor, or may be an IMU (Inertial Measurement Unit).
[0025] The imaging device 5 functions as an information acquisition device that acquires three-dimensional information of the detection target. The imaging device 5 is provided at a work site. The imaging device 5 is attached to, for example, a pole erected at the work site. The imaging device 5 according to this embodiment is a LiDAR (Light Detection and Ranging or Laser Imaging Detection and Ranging). The information acquisition device may include multiple imaging devices.
[0026] The imaging device 5 captures an image of the work machine 20. The imaging device 5 acquires point cloud data (three-dimensional point cloud) that indicates the distance from the imaging position to multiple points on the detection target. The point cloud data is three-dimensional information that makes it possible to identify the shape of the detection target, etc. In this embodiment, the imaging position is the position where the imaging device 5 is installed.
[0027] The three-dimensional information is not limited to the point cloud data, and the imaging device 5 is not limited to a LiDAR. The imaging device 5 may be a TOF (Time of Flight) sensor, a stereo camera, or the like.
[0028] As shown in FIG. 2 , the work machine 20 further includes a controller 11 , a storage device 13 , and a communication device 14 .
[0029] The storage device 13 stores shape information. The shape information is information about the shapes of the lower traveling body 21, the upper rotating body 22, the boom 31, the arm 32, and the bucket 33.
[0030] The communication device 14 communicates with the imaging device 5. The communication device 14 also communicates with a mobile terminal 7. The mobile terminal 7 is a terminal carried by an operator who manages the automatic operation of the work machine 20, and is, for example, a smartphone or a tablet terminal.
[0031] The controller 11 receives detection values acquired by the plurality of sensors 50 as input. Specifically, the controller 11 receives information about the attitude of the boom 31 detected by the boom inclination angle sensor 51. The controller 11 receives information about the attitude of the arm 32 detected by the arm inclination angle sensor 52. The controller 11 receives information about the attitude of the bucket 33 detected by the bucket inclination angle sensor 53. The controller 11 receives information about the swing angle of the upper rotating body 22 with respect to the lower traveling body 21, i.e., information about the swing attitude of the upper rotating body 22, detected by the swing angle sensor 54. The controller 11 receives information about the tilt angle of the upper rotating body 22 with respect to the horizontal plane, i.e., information about the attitude of the lower traveling body 21, detected by the inclination angle sensor 55.
[0032] The controller 11 automatically moves the slewing device 25 and the attachment 30 so that the work machine 20 performs a predetermined automatic driving operation. In other words, the controller 11 performs automatic driving of the work machine 20. The predetermined automatic driving operation is, for example, an operation of repeating excavation, lifting and swinging, soil removal, and return swing in this order.
[0033] The controller 11 includes an attitude calculation unit and a deviation calculation unit. The attitude calculation unit calculates the attitude of the detection target based on the three-dimensional information acquired by the imaging device 5 independently of the plurality of sensors 50. The deviation calculation unit calculates the deviation between the attitude of the detection target detected by the plurality of sensors 50 and the attitude of the detection target calculated by the attitude calculation unit.
[0034] The attitude calculation unit of the controller 11 calculates the inclination angles of the boom 31, the arm 32, and the bucket 33 relative to a horizontal plane as their attitudes, based on the three-dimensional information acquired by the imaging device 5. The deviation calculation unit of the controller 11 calculates the deviation between the inclination angles of the boom 31, the arm 32, and the bucket 33 detected by the plurality of sensors 50, i.e., the detected attitudes, and the inclination angles of the boom 31, the arm 32, and the bucket 33 calculated by the attitude calculation unit, i.e., the calculated attitudes.
[0035] 3 , which is a side view of the attachment 30, a first angle θA formed by an arm center line 71, which is the center line of the arm 32, and a vertical line 72 can be calculated from three-dimensional information of each of the boom 31 and the arm 32 acquired by the imaging device 5. In this embodiment, the arm center line 71 is a line connecting, in a side view, the central axis of rotation of the arm 32 with respect to the boom 31 (e.g., the central axis of an arm connecting pin) and the central axis of rotation of the bucket 33 with respect to the arm 32 (e.g., the bucket connecting pin). The first angle θA can be specified by the inclination angle of a boom center line 73, which is the center line of the boom 31 with respect to the horizontal line, i.e., a boom inclination angle θ1, and a second angle θB formed by the boom center line 73 and the arm center line 71, and the boom inclination angle θ1 is detected by the boom inclination angle sensor 51. In this embodiment, the boom center line 73 is a straight line connecting a rotation central axis of the boom 31 relative to the upper revolving body 22 (e.g., the central axis of a boom foot pin) and a rotation central axis of the arm 32 relative to the boom 31 (e.g., the arm connecting pin) in a side view. On the other hand, the second angle θB can be specified by the boom tilt angle θ1 and the tilt angle of the arm center line 71 relative to the horizontal line, i.e., the arm tilt angle θ2, and the arm tilt angle θ2 is detected by the arm tilt angle sensor 52. Therefore, the reliability of the detection values of the boom tilt angle sensor 51 and the arm tilt angle sensor 52 can be evaluated based on the magnitude of the deviation between the first angle θA specified by the boom tilt angle θ1 and the arm tilt angle θ2 detected by the sensors 51 and 52, respectively, i.e., the angle corresponding to the tilt angles θ1 and θ2, and the first angle θA calculated by the attitude calculation unit of the controller 11. That is, it is possible to evaluate whether or not there is a deviation in the detected value of either the boom tilt angle sensor 51 or the arm tilt angle sensor 52.
[0036] Based on the three-dimensional information of each of the arm 32 and the bucket 33 acquired by the imaging device 5, a third angle θC formed by a bucket opening plane line 74 along the opening plane of the bucket 33 in a side view and a vertical line 75 can be calculated. In the present embodiment, the bucket opening plane line 74 is a line connecting the tip of the bucket 33 and the central axis of rotation of the bucket with respect to the arm 32 (e.g., the bucket connecting pin). The third angle θC can be determined by the boom tilt angle θ1, the second angle θB, and a fourth angle θD formed by the arm center line 71 and the opening plane line 74 of the bucket 33. The fourth angle θD can be determined by the arm tilt angle θ2 and the tilt angle of the bucket opening plane line 74 with respect to the horizontal line, i.e., a bucket tilt angle θ3, and the bucket tilt angle sensor 53 detects the bucket tilt angle θ3. Therefore, the reliability of the detected values of the boom tilt angle sensor 51, the arm tilt angle sensor 52, and the bucket tilt angle sensor 53 can be evaluated based on the magnitude of the deviation between the third angle θC specified by the boom tilt angle θ1, the arm tilt angle θ2, and the bucket tilt angle θ3 detected by the plurality of sensors 50, i.e., the angle indicating the attitude of the bucket 33, and the third angle θC calculated by the attitude calculation unit of the controller 11. In other words, it is possible to evaluate whether or not there is a deviation in the detected value of any of the boom tilt angle sensor 51, the arm tilt angle sensor 52, and the bucket tilt angle sensor 53.
[0037] When there is a discrepancy between the value calculated by the attitude calculation unit and the detected value by the plurality of sensors 50 for at least one of the first angle θA and the third angle θC, the controller 11 transmits an error signal to the mobile terminal 7 carried by the worker. Upon receiving the error signal, the mobile terminal 7 notifies the worker of the error signal, thereby enabling the worker to take action such as stopping automatic driving.
[0038] In this way, the deviation between the attitude of the detection target detected by the plurality of sensors 50 constituting the attitude detector and the attitude of the detection target calculated based on the three-dimensional information is calculated, and the reliability of the detection values of the plurality of sensors 50 can be evaluated based on the magnitude of the deviation. This makes it possible to monitor, for example, whether the detection values of the plurality of sensors 50 deviate from an allowable range set for the detection values.
[0039] The work system 1 further includes a plurality of marks shown in Fig. 3, namely, a boom mark 81, an arm mark 82, and a bucket mark 83. The marks 81, 82, and 83 are attached to the boom 31, the arm 32, and the bucket 33, respectively, which are the detection targets. In the example shown in Fig. 3, the boom mark 81 is provided at the tip position of the boom 31, preferably at the position of the rotation center of the arm 32 with respect to the boom 31, the arm mark 82 is provided at the tip position of the arm 32, preferably at the position of the rotation center of the bucket 33 with respect to the arm 32, and the bucket mark 83 is provided at the tip of the bucket 33.
[0040] Each of the marks 81 to 83 has a high reflectivity. For example, each of the marks 81 to 83 is made of a material with a high reflectivity. This makes it possible to acquire three-dimensional information about each of the marks 81 to 83 by capturing an image of the attachment 30 using the imaging device 5. The attitude calculation unit can calculate the arm center line 71 based on the three-dimensional information about the boom mark 81 and the three-dimensional information about the arm mark 82. The attitude calculation unit can also calculate the bucket opening plane line 74 based on the three-dimensional information about the arm mark 82 and the three-dimensional information about the bucket mark 83. In this way, using the three-dimensional information about each of the marks 81 to 83 facilitates calculation of the attitude of the detection target. Note that the base end of the boom 31 is excluded from the locations where marks are to be provided because it is in a position that cannot be captured by the imaging device 5 illustrated in FIG. 1 . However, a mark may be provided at the base end of the boom 31 if the base end is in a position that can be captured.
[0041] The number and arrangement of the multiple marks are not limited. In a modification shown in Fig. 4, which is a side view of the attachment 30, two arm marks 84 and 85 are provided on the arm 32, and two bucket marks 86 and 87 are provided on the bucket 33.
[0042] The two arm marks 84, 85 are respectively arranged on the arm center line 71 at a position closer to the boom 31 than the central position of the arm center line 71 and at a position closer to the bucket 33 than the central position. The three-dimensional information of the arm marks 84, 85 enables the arm center line 71 to be calculated, and thereby enables the first angle θA formed between the arm center line 71 and the vertical line 72 to be calculated.
[0043] The two bucket marks 86, 87 are respectively arranged on the bucket opening plane line 74 at positions closer to the arm 32 than the center position of the bucket opening plane line 74 and at positions closer to the tip of the bucket 33 than the center position. The three-dimensional information of the bucket marks 86, 87 makes it possible to calculate the bucket opening plane line 74, and thereby makes it possible to calculate the third angle θC formed between the bucket opening plane line 74 and the vertical line 75.
[0044] The plurality of landmarks may be captured by a camera different from the imaging device 5. The positions of the plurality of landmarks can be identified by superimposing the coordinate system of the point cloud data captured by the imaging device 5 on the coordinate system of the plurality of landmarks captured by the camera. Furthermore, each of the plurality of landmarks may include an AR marker bearing identification information for identifying the position of the landmark. The identification information enables the information acquisition device to read the identification information and easily identify the position of the landmark.
[0045] The use of the marks is optional. For example, the posture calculation unit may specify the shapes of the arm 32 and the bucket 33 from the point cloud data, and calculate the arm center line 71 and the bucket opening plane line 74. The shape information stored in the storage device 13 is used to specify the shapes.
[0046] Next, the processing performed by the controller 11 will be described with reference to the flowchart of FIG.
[0047] The controller 11 causes the imaging device 5 to acquire reference point cloud data (step S1). The reference point cloud data is point cloud data of the work machine 20 at a preset reference position. Next, the controller 11 starts the operation of the attachment 30 by the automatic driving (step S2).
[0048] The controller 11 acquires a plurality of detection values from the plurality of sensors 50 (step S3). The plurality of detection values include the boom tilt angle θ1, the arm tilt angle θ2, and the bucket tilt angle θ3 in the current attitude of the attachment 30.
[0049] The controller 11 causes the imaging device 5 to acquire current point cloud data (step S4). The current point cloud data is point cloud data of the work machine 20 at its current position. The controller 11 calculates the difference between the reference point cloud data and the current point cloud data, and thereby extracts a portion of the current point cloud data that corresponds to the attachment 30 (step S5). This extraction may involve clustering and noise removal.
[0050] The controller 11 projects the extracted point cloud data onto a preset projection plane (step S6). The projection plane is, for example, a vertical plane.
[0051] The controller 11 identifies the positions of the marks attached to the attachment 30, i.e., the positions of the marks 81 to 83 in the example shown in Fig. 3 (step S7). The controller 11 repeats the processes of steps S3 to S7 until the positions of all of the marks 81 to 83 are identified (NO in step S8).
[0052] After identifying all of the marks 81 to 83 (YES in step S8), the controller 11 calculates the arm center line 71 and the bucket opening plane line 74 (step S9), and calculates the first angle θA and the third angle θC corresponding to the inclination angles of the arm center line 71 and the bucket opening plane line 74, respectively (step S10).
[0053] The controller 11 determines whether the values of the first angle θA and the third angle θC calculated in this manner, i.e., the values calculated for the posture of the arm 32 and the posture of the bucket 33, respectively, match the values of the first angle θA and the third angle θC specified by the values detected by the multiple sensors 50, i.e., the values detected for the posture of the arm 32 and the posture of the bucket 33, respectively (step S11). If it is determined that the calculated values of the first and third angles θA and θC match the detected values, respectively (YES in step S11), the controller 11 repeats the processes from step S3 onwards. On the other hand, if it is determined that the calculated value of at least one of the first and third angles θA and θC does not match the detected value (NO in step S11), the controller 11 transmits error information to the mobile terminal 7 (step S12).
[0054] When the multiple landmarks, for example, the landmarks 81 to 83, are used, it is possible to omit the operation of extracting the portion corresponding to the attachment 30 from the point cloud data, and in Figure 5, it is possible to omit steps S1, S4 to S6.
[0055] According to the above-described working system 1, the deviation between the posture detected by the plurality of sensors 50 constituting the posture detector and the posture calculated based on the three-dimensional information is calculated, and therefore, based on the magnitude of the deviation, it is possible to evaluate the reliability of the detection values of each of the plurality of sensors 50. For example, it is possible to monitor whether the detection values of each of the plurality of sensors 50 deviate from an allowable range set for the detection value.
[0056] 3, the boom 31, the arm 32, and the bucket 33 are the detection targets, and the multiple sensors 50 detect inclination angles θ1 to θ3 of the detection targets with respect to a horizontal plane. Meanwhile, the attitude calculation unit of the controller 11 calculates first and third angles θA and θC corresponding to the inclination angles based on the three-dimensional information. For the first and third angles θA and θC, the reliability of the detection values of the multiple sensors 50 can be evaluated based on the magnitude of the difference between the values specified by the inclination angles θ1 to θ3 detected by the multiple sensors 50, i.e., the detected values, and the calculated values calculated based on the three-dimensional information.
[0057] Furthermore, the three-dimensional information for each of the marks 81 to 87 shown in FIGS. 3 and 4 allows the posture of the detection target to be easily calculated using the three-dimensional information.
[0058] Next, a working system 101 according to a second embodiment will be described with reference to Figures 6 and 7. The second embodiment and subsequent embodiments will be described mainly with respect to differences from the first embodiment, and components common to the first embodiment will be designated by the same reference numerals.
[0059] The detection objects according to the second embodiment are the boom 31, arm 32, and bucket 33 of the work machine 20, as in the first embodiment. The work system 101 according to the second embodiment includes a controller 11 and a storage device 13 similar to the controller 11 and storage device 13 according to the first embodiment, and the controller 11 includes an attitude calculation unit and a deviation calculation unit. The attitude calculation unit calculates an angle corresponding to the inclination angle of the detection object using shape information stored in the storage device 13, i.e., information on the shapes of the boom 31, arm 32, and bucket 33, which are the detection objects, in addition to three-dimensional information acquired by the imaging device 5. The deviation calculation unit evaluates whether or not there is a deviation in the detection values of the boom inclination angle sensor 51, arm inclination angle sensor 52, and bucket inclination angle sensor 53, based on the deviation between the value calculated by the attitude calculation unit and the angle value specified by the inclination angle of the detection object detected by the multiple sensors 50.
[0060] 6 , which is a side view of the attachment 30, a boom mark 81, an arm mark 82, and a bucket mark 83 are provided at the tip of the boom 31, the tip of the arm 32, and the tip of the bucket 33, respectively, and in addition, a boom mark 80 is also provided at the center of the boom 31. Therefore, an arm center line 71 is calculated based on the three-dimensional information of the boom mark 81 and the arm mark 82, a bucket opening plane line 74 is calculated based on the three-dimensional information of the arm mark 82 and the bucket mark 83, and a boom tip center line 76, which is the center line of the tip side portion of the boom 31, can be calculated based on the three-dimensional information of the boom marks 81 and 80. The attitude calculation unit calculates a boom center line 73, which is the center line of the entire boom 31, using the shape information of the boom 31 stored in the storage device 13 and the boom tip center line 76. Specifically, the shape information of the boom 31 provides the angle between the boom tip center line 76 and the boom center line 73, thereby enabling the boom center line 73 to be suitably calculated based on the boom tip center line 76.
[0061] The marks 80 to 83 preferably have different shapes or reflectivities so that they can be distinguished from one another. This enables the attitude calculation unit to more reliably calculate the arm center line 71, the bucket opening plane line 74, and the boom tip center line 76. Even if the marks cannot be distinguished from one another, it is possible to calculate the necessary center lines (e.g., the boom center line 73 and the boom front end center line 76) based on the lines connecting the marks as long as the lines do not intersect. Therefore, it is preferable that the attitude calculation unit be configured to determine whether the lines intersect with one another and calculate the necessary center lines based on the lines only when it is determined that the lines do not intersect with one another.
[0062] Even if the boom mark 80 is not present, it is possible to identify the shape of the boom 31 from point cloud data and calculate the boom tip center line 76. The shape information stored in the storage device 13 is used to identify the shape.
[0063] The attitude calculation unit calculates a boom tilt angle θ1, which is the tilt angle of the boom 31 with respect to a horizontal plane, using the boom center line 73. The deviation calculation unit calculates the deviation between the boom tilt angle θ1 detected by the boom tilt angle sensor 51 shown in FIG. 1 and the boom tilt angle θ1 calculated by the attitude calculation unit, thereby making it possible to evaluate whether or not the detection value of the boom tilt angle sensor 51 is deviated.
[0064] The attitude calculation unit calculates a second angle θB formed by the boom center line 73 and the arm center line 71, and calculates an arm inclination angle θ2, which is the angle of the arm center line 71 with respect to the horizontal plane, based on the second angle θB and the boom inclination angle θ1 calculated as described above. The deviation calculation unit calculates the deviation between the arm inclination angle θ2 detected by the arm inclination angle sensor 52 shown in Figure 1 and the arm inclination angle θ2 calculated by the attitude calculation unit, thereby making it possible to evaluate whether or not the detection value of the arm inclination angle sensor 52 is deviated.
[0065] The attitude calculation unit calculates a fourth angle θD formed by the arm center line 71 and the bucket opening plane line 74, and calculates a bucket inclination angle θ3, which is the angle of the bucket opening plane line 74 with respect to the horizontal plane, based on the fourth angle θD and the arm inclination angle θ2 calculated as described above. The deviation calculation unit calculates the deviation between the bucket inclination angle θ3 detected by the bucket inclination angle sensor 53 shown in FIG. 1 and the bucket inclination angle θ3 calculated by the attitude calculation unit, thereby making it possible to evaluate whether or not the detection value of the bucket inclination angle sensor 53 is deviated.
[0066] Even without the marks 80 to 83, it is possible to calculate the boom center line 73, the arm center line 71, and the bucket opening plane line 74 by identifying the shapes of the boom 31, the arm 32, and the bucket 33 from point cloud data. The shape information stored in the storage device 13 is used to identify the shapes.
[0067] Next, the processing performed in the second embodiment will be described with reference to the flowchart of FIG.
[0068] First, the controller 11 causes the imaging device 5 to acquire reference point cloud data (step S21). The reference point cloud data is point cloud data of the work machine 20 at a reference position. Next, the controller 11 starts the operation of the attachment 30 by automatic driving (step S22).
[0069] The controller 11 acquires a plurality of detection values from the plurality of sensors 50 (step S23). The plurality of detection values include the boom tilt angle θ1, the arm tilt angle θ2, and the bucket tilt angle θ3 in the current attitude of the attachment 30.
[0070] The controller 11 causes the imaging device 5 to acquire current point cloud data (step S24). The current point cloud data is point cloud data of the work machine 20 at its current position. The controller 11 calculates the difference between the reference point cloud data and the current point cloud data, thereby extracting a portion of the current point cloud data that corresponds to the attachment 30 (step S25). This extraction may involve clustering or noise removal.
[0071] The controller 11 projects the extracted point cloud data onto a preset projection plane (step S26). The projection plane is, for example, a vertical plane. The controller 11 identifies the positions of the marks 80 to 83 (step S27). The controller 11 repeats the processes of steps S23 to S27 until the positions of all of the marks 80 to 83 have been identified (NO in step S28).
[0072] After identifying the positions of all of the marks 80 to 83 (YES in step S28), the controller 11 calculates the boom tip side center line 76 (step S29), and further calculates the boom center line 73 from the boom tip side center line 76 using shape information of the boom 31 (step S30).
[0073] The attitude calculation unit of the controller 11 calculates the boom tilt angle θ1, the arm tilt angle θ2, and the bucket tilt angle θ3 (step S31). The deviation calculation unit of the controller 11 determines whether the calculated values of the tilt angles θ1 to θ3 match the detected values detected by the multiple sensors 50 (step S32). If it is determined that the calculated values of the tilt angles θ1 to θ3 match the detected values of the tilt angles θ1 to θ3 (YES in step S32), the controller 11 repeats the processing from step S23 onwards. On the other hand, if it is determined that the calculated value of any of the tilt angles θ1 to θ3 does not match the detected value (NO in step S32), the controller 11 transmits error information to the mobile terminal 7 (step S33).
[0074] When the mark 80 is used, it is possible to omit the operation of extracting the portion corresponding to the attachment 30 from the point cloud data, and to omit steps S21, S24 to S26 in FIG.
[0075] According to the above-described working system 101, the orientation of the detection target is calculated using the shape information stored in the storage device 13 in addition to the three-dimensional information. The use of the shape information makes it easier to calculate the orientation of the detection target.
[0076] Next, a working system 201 according to a third embodiment will be described with reference to FIGS. 8 and 9. FIG.
[0077] The detection object according to this embodiment is the boom 31, arm 32, and bucket 33 of the work machine 20, as in the second embodiment. The work system 101 according to this embodiment includes a controller 11 and a storage device 13 similar to the controller 11 and storage device 13 shown in FIG. 1. The controller 11 includes an attitude calculation unit and a deviation calculation unit. As in the second embodiment, the attitude calculation unit calculates the tilt angle of the detection object using shape information stored in the storage device 13, i.e., information on the shapes of the boom 31, arm 32, and bucket 33, in addition to three-dimensional information acquired by the imaging device 5. On the other hand, the third embodiment does not require the marks 80 to 83 according to the second embodiment.
[0078] The controller 11 operates a three-dimensional model of the attachment 30 as shown in FIG. 8 using detection values of multiple sensors 50. The controller 11 calculates a current boom area, which is the area of the current boom 31 in the three-dimensional model, at a predetermined timing. At the same time, the controller 11 causes the imaging device 5 to acquire current point cloud data, which is point cloud data of the actual work machine 20. The controller 11 cuts out boom point cloud data, which is point cloud data corresponding to the current boom area, from the current point cloud data acquired in this manner. For this cutout, the controller 11 uses shape information of the boom 31 stored in the storage device 13.
[0079] The controller 11 calculates the proportion of the boom point cloud data that occupies the current boom area in the three-dimensional model, i.e., the occupancy rate of the boom point cloud data. The higher the occupancy rate, the smaller the deviation between the three-dimensional model and the actual attachment 30. In other words, the deviation between the detected attitude, which is the attitude of the boom 31 specified by the detection value of the boom tilt angle sensor 51, and the calculated attitude, which is the attitude of the boom 31 calculated by the attitude calculation unit, is smaller. Therefore, the reliability of the detection value of the boom tilt angle sensor 51 can be evaluated based on the occupancy rate.
[0080] By performing the same processing as described above for each of the arm 32 and the bucket 33, the reliability of the detection value of the arm inclination angle sensor 52 and the reliability of the detection value of the bucket inclination angle sensor 53 can also be evaluated.
[0081] Next, the processing performed in the third embodiment will be described with reference to the flowchart of FIG.
[0082] First, the controller 11 acquires the position of the work machine 20 and the orientation of the upper rotating body 22 of the work machine 20 (step S41). The controller 11 places a three-dimensional model in a position in virtual space that corresponds to the acquired position of the work machine 20, and matches the orientation of the upper rotating body in the three-dimensional model to the acquired orientation of the upper rotating body 22 (step S42). The controller 11 starts the operation of the three-dimensional model using detection values from the multiple sensors 50 (step S43).
[0083] At a predetermined timing, the controller 11 calculates the area of the current boom 31 in the three-dimensional model, i.e., the current boom area (step S44). At the same timing, the controller 11 causes the imaging device 5 to acquire point cloud data (step S45), and extracts point cloud data corresponding to the current boom area, i.e., boom point cloud data, from the point cloud data (step S46).
[0084] The controller 11 calculates the proportion of the boom point cloud data that occupies the current boom area, i.e., the occupancy rate of the boom point cloud data (step S47). The controller 11 determines whether the occupancy rate is equal to or greater than a preset threshold (step S48). If it is determined that the occupancy rate is equal to or greater than the threshold (YES in step S48), the controller 11 repeats the processes from step S44 onwards. On the other hand, if it is determined that the occupancy rate is smaller than the threshold (NO in step S48), the controller 11 transmits error information to the mobile terminal 7 (step S49).
[0085] Next, a work system 301 according to a fourth embodiment will be described with reference to Figures 10 and 11. The detection target according to the fourth embodiment is the upper rotating body 22 of the work machine 20, and the reliability of the detection value of the swing angle sensor 54 that detects the swing angle of the upper rotating body 22 is evaluated.
[0086] The swing angle sensor 54 detects the swing angle of the upper swing body 22 relative to the undercarriage 21 of the work machine 20. In other words, the swing angle sensor 54 detects the swing posture of the upper swing body 22 relative to the undercarriage 21. The swing angle sensor 54 detects the swing angles of the upper swing body 22 corresponding to a first swing posture and a second swing posture, which are different from each other, as shown by a two-dot chain line and a solid line, respectively, in Figure 10, which is a plan view of the work machine 20. The first swing posture is a reference posture, and the center line of the attachment 30 in this reference posture, i.e., the attachment center line, is set as a reference line 77. The angle formed by the attachment center line 78 in the second swing posture and the reference line 77 corresponds to the difference between a first detection value, which is a detection value in the first swing posture, and a second detection value, which is a detection value in the second swing posture.
[0087] On the other hand, the working system 301 includes a controller 11 similar to the controller 11 shown in FIG. 1, and the controller 11 includes a difference calculation unit, an attitude calculation unit, and a deviation calculation unit.
[0088] The difference calculation unit calculates the difference between the first detection value and the second detection value as the rotation angle of the upper rotating body 22 from the reference line 77. That is, in the fifth embodiment, the rotation angle sensor 54 and the difference calculation unit configure an attitude detector, and the attitude detector detects the difference, i.e., the rotation angle of the upper rotating body 22 from the reference line 77, as a value indicating the attitude of the upper rotating body 22.
[0089] 1 or another information acquisition device acquires three-dimensional information of the work machine 20, and calculates the swing angle of the upper rotating body 22 from the reference line 77 based on the three-dimensional information as a value indicating the attitude of the upper rotating body 22. In other words, the controller 11 calculates the angle formed by the reference line 77 and the attachment center line 78 in the second swing attitude. The deviation calculation unit of the controller 11 calculates the deviation between the difference in the swing angles detected by the swing angle sensor 54 and the difference calculation unit, and the swing angle calculated by the attitude calculation unit, thereby enabling the reliability of the detection value of the swing angle sensor 54 to be evaluated.
[0090] Next, the processing performed in the fifth embodiment will be described with reference to the flowchart of FIG.
[0091] First, the controller 11 places the upper rotating body 22 in the first rotating position, i.e., the reference position, indicated by the two-dot chain line in Figure 10, and then causes the image capture device 5 to acquire reference point cloud data (step S61). The reference point cloud data is point cloud data of the work machine 20 at a reference position. Next, the controller 11 starts the operation of the work machine 20 (step S62). During the operation, the orientation of the undercarriage 21 is not changed.
[0092] The controller 11 acquires a detection value from the sensor 50, specifically, the swing angle sensor 54 (step S63). The detection value is the swing angle of the upper swing body 22 with respect to the lower traveling body 21.
[0093] The controller 11 causes the imaging device 5 to acquire current point cloud data (step S64). The current point cloud data is point cloud data of the work machine 20 at its current position. The controller 11 calculates the difference between the reference point cloud data and the current point cloud data, thereby extracting a portion of the current point cloud data that corresponds to the attachment 30 (step S65). This extraction may involve clustering or noise removal.
[0094] The controller 11 projects the extracted point cloud data onto a predetermined projection plane (step S66). The projection plane is, for example, a horizontal plane. On the projection plane, the controller 11 calculates the center line of the attachment 30 in the first swing posture, i.e., the attachment center line (step S67), and sets the attachment center line as the reference line 77 (step S68).
[0095] Next, the controller 11 rotates the upper rotating body 22 by a predetermined angle to set it in the second rotating posture shown in Fig. 10, and again acquires a detection value from the sensor 50, i.e., the rotation angle sensor 54 (step S69). The detection value is the rotation angle of the upper rotating body 22 with respect to the lower traveling body 21.
[0096] At this point, the controller 11 causes the imaging device 5 to acquire the current point cloud data again (step S70). The controller 11 calculates the difference between the reference point cloud data and the newly acquired current point cloud data, thereby extracting a portion of the current point cloud data that corresponds to the attachment 30 (step S71).
[0097] The controller 11 projects the extracted point cloud data onto the projection plane (step S72). On the projection plane, the controller 11 calculates the center line of the attachment 30, i.e., an attachment center line 78 (step S73), and calculates the angle between the attachment center line 78 and the reference line 77 (step S74).
[0098] The controller 11 determines whether the calculated swing angle calculated based on the point cloud data as described above, i.e., the angle between the attachment center line 78 and the reference line 77, matches the difference between the swing angle of the upper swing body 22 detected by the swing angle sensor 54 when the reference line 77 was set in the first swing posture and the swing angle of the upper swing body 22 detected by the swing angle sensor 54 when the attachment center line 78 was calculated in the second swing posture, i.e., the detected swing angle (step S75). If it is determined that the calculated swing angle matches the detected swing angle, i.e., the difference between the detection values of the swing angle sensor 54 in the first and second swing postures (YES in step S75), the controller 11 repeats the processing from step S69 onwards. On the other hand, when it is determined that the calculated turning angle does not match the detected turning angle (NO in step S75), the controller 11 transmits error information to the mobile terminal 7 (step S76).
[0099] According to the work system 301 described above, the swing angle sensor 54 and the difference calculation unit of the controller 11 detect the swing angle of the upper swing body 22 that is the detection target, while the attitude calculation unit of the controller 11 calculates the swing angle of the upper swing body 22 from the reference line 77 based on the three-dimensional information. Therefore, the deviation calculation unit of the controller 11 calculates the deviation between the former swing angle, i.e., the detected swing angle, and the latter swing angle, i.e., the calculated swing angle, thereby enabling the reliability of the detection value of the swing angle sensor 54 to be evaluated based on the magnitude of the deviation.
[0100] Next, a work system 401 according to a fifth embodiment will be described with reference to Figures 12 and 13. The detection target according to the fifth embodiment is the undercarriage 21 of the work machine 20, and the reliability of the detection value of the inclination angle sensor 55 that detects the inclination angle of the undercarriage 21 relative to the horizontal plane is evaluated.
[0101] 1 , the controller 11 includes an attitude calculation unit and a deviation calculation unit. The attitude calculation unit calculates the inclination angle of the undercarriage 21 with respect to a horizontal plane based on the acquired three-dimensional information as a value indicating the attitude of the undercarriage 21. The deviation calculation unit calculates the deviation between the inclination angle of the undercarriage 21 detected by the inclination angle sensor 55, i.e., the detected value, and the inclination angle of the undercarriage 21 calculated by the attitude calculation unit, i.e., the calculated value.
[0102] A plurality of marks are provided on the undercarriage 21. In the example shown in Figure 12, which is a perspective view of the work machine 20, a front mark 88F and a rear mark 88R are provided on each of the pair of left and right crawlers 60 of the undercarriage 21. The front mark 88F is located on the outer surface of an idler, which is the front wheel of the crawler 60, and on the central axis of the idler, and the rear mark 88R is located on the outer surface of a drive tumbler, which is the rear wheel of the crawler 60, and on the central axis of the drive tumbler.
[0103] The controller 11 extracts a portion corresponding to the undercarriage 21 from the point cloud data acquired by the imaging device 5 and projects the portion onto a predetermined projection plane. The projection plane is, for example, a vertical plane. The controller 11 extracts data on the front and rear marks 88F, 88R provided on the same crawler 60, and calculates the crawler center line 91, which is a straight line connecting the front and rear marks 88F, 88R, based on the extracted data.
[0104] The attitude calculation unit calculates the angle between the crawler center line 91 and a horizontal plane, i.e., the inclination angle. The deviation calculation unit calculates the deviation between the inclination angle calculated by the attitude calculation unit, i.e., the calculated inclination angle, and the inclination angle detected by the inclination angle sensor 55, i.e., the detected inclination angle, thereby enabling the reliability of the detection value of the inclination angle sensor 55 to be evaluated.
[0105] It is also possible to specify the shape of the undercarriage 21 from the point cloud data and calculate the crawler center line 91 without using the front and rear marks 88F, 88R. The shape information stored in the storage device 13 is used to specify the shape.
[0106] Next, the processing performed in the fifth embodiment will be described with reference to the flowchart of FIG.
[0107] The controller 11 causes the imaging device 5 to acquire reference point cloud data (step S81). The reference point cloud data is point cloud data of the work machine 20 at a reference position. Next, the controller 11 causes the upper rotating body 22 to start operating without causing the lower traveling body 21 to perform a traveling operation (step S82).
[0108] The controller 11 acquires a detection value from the inclination angle sensor 55 (step S83). The detection value is the inclination angle of the undercarriage 21 with respect to the horizontal plane in the current attitude of the work machine 20.
[0109] The controller 11 causes the imaging device 5 to acquire current point cloud data (step S84). The current point cloud data is point cloud data of the work machine 20 at its current position. The controller 11 calculates the difference between the reference point cloud data and the current point cloud data, thereby extracting a portion of the current point cloud data that corresponds to the undercarriage 21 (step S85). This extraction may involve clustering or noise removal.
[0110] The controller 11 projects the extracted point cloud data onto a predetermined projection plane (step S86). The projection plane is, for example, a vertical plane. The controller 11 identifies the positions of the front and rear markers 88F, 88R (step S87). The controller 11 repeats the processes from step S83 onwards until the positions of all of the front and rear markers 88F, 88R have been identified (NO in step S88). On the other hand, after identifying the positions of all of the markers 88F, 88R (YES in step S88), the controller 11 calculates the crawler center line 91 connecting the front and rear markers 88F, 88R (step S89) and calculates the angle between the crawler center line 91 and a horizontal plane (step S90).
[0111] The controller 11 determines whether the tilt angle calculated in this manner, i.e., the calculated tilt angle, matches the tilt angle detected by the tilt angle sensor 55, i.e., the detected tilt angle (step S91). If it is determined that the calculated tilt angle matches the detected tilt angle (YES in step S91), the controller 11 repeats the processes from step S83 onwards. On the other hand, if it is determined that the calculated tilt angle does not match the detected tilt angle (NO in step S91), the controller 11 transmits error information to the portable terminal 7 (step S92).
[0112] When the front and rear markers 88F, 88R are used, it is possible to omit the operation of extracting the part corresponding to the lower running body 21 from the point cloud data, that is, to omit steps S81, S84 to S86 in Figure 13.
[0113] According to the work system 401 described above, the inclination angle sensor 55 constituting the attitude detector detects the inclination angle of the lower running body 21 with respect to a horizontal plane as the attitude of the lower running body 21 to be detected, and the attitude calculation unit calculates the inclination angle of the lower running body 21 with respect to the horizontal plane based on the acquired three-dimensional information. The deviation calculation unit calculates the deviation between the inclination angle detected by the inclination angle sensor 55 and the inclination angle calculated based on the three-dimensional information, thereby making it possible to evaluate the reliability of the detection value of the inclination angle sensor 55 based on the magnitude of the deviation.
[0114] The above-described embodiments are illustrative examples and do not limit the scope of the present invention. The disclosed specific configurations can be modified as appropriate. Furthermore, the functions and effects of the present invention are not limited to those described in the above embodiments.
[0115] As described above, a work system is provided that enables monitoring of detected values for the attitude of a detection target. The work system includes a lower traveling body, an upper revolving body, a boom, an arm, a tip attachment, an attitude detector, an information acquisition device, an attitude calculation unit, and a deviation calculation unit. The upper revolving body is rotatably mounted on the lower traveling body. The boom is connected to the upper revolving body so as to be rotatable in the vertical direction. The arm is connected to the boom so as to be rotatable in the vertical direction. The tip attachment is rotatably connected to the arm. The attitude detector detects the attitude of at least one detection target, and the at least one detection target is selected from the lower traveling body, the upper revolving body, the boom, the arm, and the tip attachment. The information acquisition device acquires three-dimensional information of the detection target. The attitude calculation unit calculates the attitude of the detection target based on the three-dimensional information acquired by the information acquisition device. The deviation calculation unit calculates the deviation between the attitude detected by the attitude detector and the attitude calculated by the attitude calculation unit.
[0116] By calculating the deviation between the posture detected by the posture detector and the posture calculated based on the three-dimensional information, the work system enables the reliability of the detection value by the posture detector to be evaluated based on the magnitude of the deviation, thereby making it possible to monitor, for example, whether the detection value by the posture detector deviates from an acceptable range set for the detection value.
[0117] When the at least one detection target includes the boom, the arm, and the tip attachment, it is preferable that the attitude detector detects the inclination angle of the detection target with respect to a horizontal plane for the attitude of the detection target, and the attitude calculation unit calculates the inclination angle of the detection target with respect to the horizontal plane or an angle corresponding to the inclination angle for the attitude of the detection target.
[0118] For example, when the at least one detection target includes the upper rotating body, it is preferable that the attitude detector detects the rotation angle of the upper rotating body from a reference line for the attitude of the upper rotating body, and the attitude calculation unit calculates the rotation angle of the upper rotating body from the reference line for the attitude of the upper rotating body.
[0119] For example, when the at least one detection object includes the lower running body, it is preferable that the attitude detector detects the inclination angle of the lower running body relative to a horizontal plane for the attitude of the lower running body, and the attitude calculation unit calculates the inclination angle of the detection object relative to a horizontal plane for the attitude of the lower running body.
[0120] It is preferable that the work system further includes a mark attached to the detection target, and the information acquisition device is configured to acquire three-dimensional information of the mark.
[0121] It is preferable that the work system further includes a storage device that stores shape information, which is information about the shape of the detection target, and the posture calculation unit is configured to calculate the posture of the detection target using the three-dimensional information and the shape information stored in the storage device.
Claims
1. A work system comprising: a lower running body; an upper rotating body rotatably mounted on the lower running body; a boom connected to the upper rotating body so as to be rotatable in the vertical direction; an arm connected to the boom so as to be rotatable in the vertical direction; a tip attachment rotatably connected to the arm; a posture detector that detects the posture of at least one detection object selected from among the lower running body, the upper rotating body, the boom, the arm and the tip attachment; an information acquisition device that acquires three-dimensional information of the detection object independently of the posture detector; a posture calculation unit that calculates the posture of the detection object based on the three-dimensional information acquired by the information acquisition device; and a deviation calculation unit that calculates the deviation between the posture detected by the posture detector and the posture calculated by the posture calculation unit.
2. A work system as described in claim 1, wherein the at least one detection target includes the boom, the arm and the tip attachment, the attitude detector detects the inclination angle of the detection target relative to a horizontal plane for the attitude of the detection target, and the attitude calculation unit calculates the inclination angle of the detection target relative to the horizontal plane or an angle corresponding to the inclination angle for the attitude of the detection target.
3. A work system as described in claim 1, wherein the at least one detection object includes the upper rotating body, the attitude detector detects the rotation angle of the upper rotating body from a reference line for the attitude of the upper rotating body, and the attitude calculation unit calculates the rotation angle of the upper rotating body from the reference line for the attitude of the upper rotating body.
4. A work system as described in claim 1, wherein the at least one detection object includes the lower running body, the attitude detector detects the inclination angle of the lower running body relative to a horizontal plane for the attitude of the lower running body, and the attitude calculation unit calculates the inclination angle of the detection object relative to the horizontal plane for the attitude of the lower running body.
5. A work system as claimed in any one of claims 1 to 4, further comprising a mark attached to the detection object, and the information acquisition device is configured to acquire three-dimensional information of the mark.
6. A work system according to any one of claims 1 to 4, further comprising a storage device that stores shape information that is information about the shape of the detection target, and the orientation calculation unit is configured to calculate the orientation of the detection target using the three-dimensional information and the shape information stored by the storage device.
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