A moment control assistant with voice guidance

Abstract

The invention relates to a control assistant designed for industrial machines with hydraulic arms, capable of replacing conventional instantaneous load-limiting systems used in the prior art. The assistant prevents potential accidents by guiding and alerting operators through voice commands.

Description

[0001] A MOMENT CONTROL ASSISTANT WITH VOICE GUIDANCE

[0002] TECHICAL FIELD

[0003] The invention relates to a control assistant designed for industrial machines with hydraulic arms, capable of replacing conventional instantaneous load-limiting systems used in the prior art. The assistant prevents potential accidents by guiding and alerting operators through voice commands.

[0004] BACKGROUND

[0005] From past to present, industrial machines equipped with hydraulic arms have been frequently used for lifting and loading operations in areas where human strength is insufficient, particularly in the construction sector. Construction sites are hazardous zones where accidents often occur during lifting and loading activities. Accidents involving lifting and loading equipment are primarily caused by the excessive limitation imposed by load-limiting systems on industrial machines with hydraulic arms. This excessive limitation can frustrate operators, leading them to disable the system to bypass the restrictions, thereby increasing the risk of accidents.

[0006] In various fields such as the construction sector, railway systems, and maritime operations, industrial machines equipped with hydraulic arms are extensively used for lifting and loading tasks. These machines, depending on their working environment, operate on water, railways, or land using wheeled or tracked systems, and form the backbone of the supply chain. The flow of global trade volume is directly proportional to the performance of the supply chain. Unintended accidents involving industrial machines with hydraulic arms lead to delays in the supply chain and, more critically, human casualties. Occupational accidents with these machines often occur due to capacity overloads or operator errors.

[0007] In the use of industrial machines with hydraulic arms, the weight of the load being lifted is detected by load-limiting systems during the lifting process. However, when the same load is lifted at different angles or lengths, the load-limiting systems (excluding weight measurement via load cells) perceive varying weight values. To prevent these variations from posing safety risks, the limits of the safety systems are set to lower thresholds. Setting the limits to lower thresholds reduces the operational capacities of industrial machines with hydraulic arms. Consequently, businesses operating these machines in the field, faced with capacity reductions in load-limiting systems, often deploy machines with capacities exceeding the weight of the loads to be lifted. Operating machines with capacities exceeding the requirements of the task leads to losses in time, money, and productivity. On the other hand, untrained operators, aiming to utilize the machine's capacity to its fullest, may disable the loadlimiting moment control systems. Disabling the moment control system and operating cranes without limits creates a foundation for workplace accidents.

[0008] There are two distinct scenarios associated with the moment control system. The first involves lifting a load that exceeds the machine's capacity. A similar problem arises from the incomplete disconnection of a fixed load's attachments. For instance, when moving an old silo or lathe machine, some of its mounting connections to the ground might be overlooked, and the operator may attempt to lift the load, believing it to be free. In such a situation, the load exhibits a much greater weight than expected. During this process, the machine operator, assuming the load's weight is within the machine's capacity, may disable the moment control system, leading to accidents.

[0009] The second scenario leading to accidents occurs during the transport of a safely lifted load to a different location. For example, if a load is lifted and then needs to be moved further away, the hydraulic extension booms are extended to transport the load to the desired position. During this extension, exceeding the extension limit causes accidents. In both scenarios, the common factor is that accidents could be prevented by a properly functioning moment control system.

[0010] In existing moment control systems, operators are audibly alerted, such as through a siren, in the event of an overload. At the same time, the system displays on a screen the specific actions the operator should take to prevent an accident. In these systems, colored arrows on the screen indicate which movements are safe for the operator to perform. By following these arrows, the operator executes load-reducing and thus safer actions.

[0011] AIM OF THE INVENTION

[0012] The aim of the invention is to guide the operator through voice commands during the operation of industrial machines with hydraulic arms to prevent potential accidents. A voice-guided moment control system has been designed to alert the operator in cases of incorrect usage and provide verbal instructions on the correct actions to take. Unlike the existing technology, the invention provides not only visual guidance on a screen but also delivers the correct actions as voice commands to the operator via a speaker inside the cabin. For example, the operator is audibly notified with phrases such as, “Warning: Overload. Retract the booms or lower the cable.” This ensures real-time verbal guidance to the operator. In this way, the operator is guided through voice commands without the need to look at the screen during operation. If the operator inadvertently performs an incorrect action during this guidance, the moment control system prevents the action from being executed. However, since there is no feedback provided to the operator in such cases, the operator may struggle to understand what went wrong. Unlike existing systems, the invention enhances operator awareness during critical operations by providing voice warnings when an incorrect action is attempted. For example, the system alerts the operator with messages such as, “Warning: Overload. You are attempting an incorrect action. Please pull the boom retraction joystick towards you.” This ensures that the operator is promptly informed and guided to take the correct action. The desired technical effect at this point is to reduce workplace accidents, where even the smallest benefit can mean saving a life. Unlike existing techniques, the invention also enables sequential instructions to be communicated to the operator. For example, the system can provide guidance such as, “First, move the boom joystick to the right, then pull it towards yourself.” The correct sequence of actions is conveyed to the operator, and each step in the sequence is monitored to ensure it is performed. If necessary, the operator is reminded of the next action in the sequence.

[0013] LIST OF FIGURES

[0014] Figure 1: Example moment control information screen.

[0015] Figure 2: General view of a truck-mounted foldable mobile hydraulic crane. Figure 3: Example load diagram of a foldable mobile crane.

[0016] Figure 4: Components of the control system in a mobile crane.

[0017] Numbered References in the Figures:

[0018] 1. Hydraulic cylinder

[0019] 2. Hydraulic cylinder

[0020] 3. Hydraulic cylinder

[0021] 4. Main boom 5. Vertical boom

[0022] 6. Folding boom

[0023] 7. Extension boom

[0024] 8. Load

[0025] 9. Operator control

[0026] 10. Main control unit

[0027] 11. Machine movements

[0028] 12. Pressure sensor

[0029] 13. Pressure sensor

[0030] 14. Tilt sensor

[0031] 15. Tilt sensor

[0032] 16. Length sensor

[0033] 17. Voice transmission unit

[0034] 18.GSM / GPRS unit

[0035] DETAILED DESCRIPTION OF THE INVENTION

[0036] The moment control system subject to the invention includes a voice command unit that functions as an operator assistant, providing voice commands and warnings to the operator of the industrial machine. This feature ensures uninterrupted operation by allowing the operator to use the machine without needing to look at any screens. By enhancing operator awareness during critical operating conditions, this usage method reduces workplace accidents and prevents the overuse of machines beyond their capacity.

[0037] In systems available in the current literature, when the capacity is exceeded, an overload sound warning is issued, and the necessary actions for the operator to take are indicated through lighting or screen visuals. An example of the screen visuals used in traditional moment systems is provided in Figure 1. In the mentioned prior art, the operator is guided by the color-coded arrows displayed on the screen over the movable points of the machine. The moment control system of the invention, unlike existing systems, provides guidance to the operator during overload situations not only through screen displays but also via voice commands to ensure safe operation. Therefore, this system allows the operator to perform the necessary actions without looking at a screen by delivering the correct instructions through a voice command unit. Thus, the system ensures that even an operator using the machine for the first time can easily and safely perform critical movements in a secure manner.

[0038] To better explain the invention, the system will be described using an example industrial machine (mobile crane). However, the information provided here is not intended to impose any limitations. The invention can be utilized on any industrial machine that collects data from its components during operation.

[0039] Foldable mobile cranes are typically hydraulic machines mounted on vehicles, used for lifting and loading operations. Figure 2 shows the general view of a truckmounted foldable mobile hydraulic crane. The movement of the first hydraulic cylinder (1) adjusts the angle between the main boom (4) and the vertical boom (5). The movement of the second hydraulic cylinder (2) adjusts the angle between the main boom (4) and the folding boom (6). The folding operation on the vehicle is performed using the first hydraulic cylinder (1) and the second hydraulic cylinder (2). The movement of the third hydraulic cylinder (3) enables the forward and backward motion of the telescoping extension booms (7). The load (8) is lifted using a hook. The main boom (4) and the folding boom (6) facilitate the lifting and lowering of the load (8) from the ground (8.2). The extension booms (7) allow the forward and backward movement of the load (8) relative to the pivot center (8.1). The pivot center point (8.1) enables 360° rotation of the load (8) to the left and right. During these movements, various stresses occur on the machine depending on the load (8). The pressures in the hydraulic cylinders also vary according to the vertical and horizontal distance of the load (8) from the pivot center point (8.1).

[0040] Graphs that determine how far a lifted weight should move vertically and horizontally are called load diagrams. Figure 3 provides the load diagram for an example foldable mobile crane. This diagram illustrates the operational range of the machine based on the weight of the lifted load. Each square on the diagram corresponds to one meter. The vertical axis on the left represents the height in meters, while the horizontal axis at the bottom indicates the horizontal distance in meters. The vertical axis on the right and the horizontal axis at the top indicate angles in degrees. Along the horizontal axis, under the booms, weights in kilograms and lengths in millimeters are specified at regular intervals. These values represent the maximum weight allowed by the manufacturer for lifting at the corresponding lengths during machine operation. Users must not exceed these limits. For the safe operation of the machine, it must be used in accordance with this graph. Moment control systems are designed to ensure that the operator uses the machine within the parameters defined by this graph.

[0041] In the load diagram, the movement projections of the booms during lifting and lowering differ. Referring to the lifting and lowering projection for the 14,000-8,400 kg range at the bottom of the graph in Figure 3, when lowering the load to the ground, the distance of the load to the center should follow a fixed boom distance after approximately 30°. In such a case, while lowering the load, the moment control system issues a warning and does not permit the lowering to proceed. The system allows operations to proceed only after moment-reducing actions are performed to create a safe working area. By reducing the moment, the pressures in the hydraulic cylinders are decreased. This is achieved by retracting the extension booms (7) to bring the load closer to the center. In existing literature, moment control systems, such as the example shown in Figure 1, provide information to the operator by color-coding or displaying / not displaying arrows on the movable points of the machine.

[0042] Figure 4 presents a block diagram of the components in the control system of the example mobile crane. During the lifting and lowering of the load by the mobile crane, the lifting boom cylinder pressure (12) and the folding boom cylinder pressure (13) increase or decrease depending on the weight of the load. Similarly, data received by the lifting boom tilt sensor (14) and the folding boom tilt sensor (15) also change during the lifting and lowering movements of the load. During the transport of the lifted load farther from or closer to the pivot center point using the extension booms, the distance to the center is measured by the proximity sensor (16). The boom movements necessary for lifting, lowering, or transporting the load to a different location are performed by the operator. Figure 2 illustrates possible operator control (movement requests) (9) scenarios that may occur during these operations. In a standard lifting operation, the operator uses hydraulic valve levers, joysticks located within the cabin, or joysticks on a remote control to perform the lifting motion. As a result of the operator control (9), the type of movement request is detected by the main control unit (10), which governs the controls, a feature present in all industrial machines with hydraulic arms as described in the literature. During this process, the pressure sensors (12, 13), tilt sensors (14, 15), and proximity sensor (16) detect the pressures exerted by the load on the hydraulic cylinders (1 , 2, 3), the tilt angles of the booms, and the distance to the pivot center point. The main control unit (10) calculates whether the system is within the safe pressure limit range based on the data received from the pressure sensors (12, 13), tilt sensors (14, 15), and proximity sensor (16) for the crane's current position. If the values are within the safe range, the movement request initiated by the operator is executed, and the load is lifted. If the values are not within the safe range, the operator is alerted with a voice warning and is also shown on a screen which actions are permitted for the lifting process. Since only the lowering movement is allowed, the indicator for the lowering joint is displayed in green on the screen, while other indicators are shown in red, warning the operator. The system described up to this point corresponds to the instantaneous load-limiting systems present in the technical literature.

[0043] The operating principle of all load-limiting systems included in the known state of the art is the same. The operating limits of the industrial machine being monitored are predefined within the machine's main control unit (10) and used as a reference. During operation, real-time data corresponding to these reference values are obtained from the sensors on the machine. The real-time data is then compared with the reference values in the main control unit (10). If the defined limits in the main control unit (10) are approached or reached, the movement is electrically restricted by the main control unit (10). After this restriction, visual commands are provided to the operator to guide the machine back to a safe operating zone. Alternatively, a warning indicating that further movement is not allowed is conveyed to the operator using a standard sound (e.g., a beep).

[0044] The system subject to our invention differs from the prior art by incorporating a voice command unit (17) capable of real-time guidance. The voice command unit (17) includes a memory unit, a signal detector, and a speaker. The main control unit (10) generates signals corresponding to the movements that the operator can or cannot perform. Subsequently, these signals are sent to the voice command unit (17). For example, if the operator attempts to perform an upward movement using the hydraulic arms of the industrial machine, and this movement is deemed risky under the current conditions, the main control unit (10) restricts the upward movement and sends a signal to the voice command unit (17) indicating that the upward movement should not be performed. Thus, within the main control unit (10), all potential joint movements that can be approved or disapproved during operation are recorded, and a function for generating a signal corresponding to each scenario is available. In the voice command unit (17), a signal detector is present to identify the type of signals sent by the main control unit (10) for all joint movements that can be executed by a machine operator. The function of the signal detector is to determine the type of the incoming signal. The memory unit stores a database of voice commands corresponding to each possible signal. The signal detector identifies the type of the incoming signal and matches it with the corresponding voice command in the database. Subsequently, the voice file associated with the signal is played to the operator through the speaker by the signal detector. The mentioned signal detector can function as a processor.

[0045] As described above, the voice files to be played by the voice command unit (17) are stored in the memory unit, and when a signal matching the stored sounds is sent by the main control unit (10), the playback of the corresponding sound is carried out by the voice command unit (17). It was also mentioned that the playback of the sound is technically enabled by a signal detector. Therefore, to activate the technique described in the invention, the memory unit within the voice command unit (17) must be loaded with sounds corresponding to all the signals that will be sent by the main control unit (10). At this point, the sounds provided as feedback to the operator are transferred to the voice command unit (17) in two ways. In the first method, the data is recorded onto a memory card, which is then inserted into the voice command unit. In this setup, the voice command unit (17) includes a card reader. In the second method, the sound data is transmitted to the voice command unit (17) via the CANBUS protocol. In the transmission of sound files via the CANBUS protocol, an external computer program is used. However, this program does not contribute to the technical effect of the invention. The connection established via the CANBUS protocol is utilized to match the sound data with the signals from the main control unit (10) using an interface on a mobile device (e.g., computer, tablet, phone). The interface is used for tasks such as loading sound data onto the voice command unit (17) from the CANBUS line or indexing the already loaded sound files. The indexing mentioned here is performed to enable the signal detector (processor) to identify which sound files should be played. The main control unit (10) generates a signal indicating which indexed sound should be played by the voice command unit (17). This signal is detected by the signal detector within the voice command unit (17). The sound data corresponding to the signal is then played through the speaker by the signal detector.

[0046] Within the invention, voice commands can also be generated for situations where at least two consecutive movements are required to reach the safe operating zone. If multiple voice commands need to be played in sequence, the main control unit (10) sends the signals or sound indices along with the order and frequency of playback. After the signal detector in the voice command unit (17) receives the sequence and count of voice commands, it provides feedback to the main control unit (10) confirming that the settings have been received. After the voice command unit (17) plays the sound file, it generates a feedback signal to be sent to the main control unit (10), confirming that the data has been played. Once the playback process is complete, the voice command unit (17) again provides feedback to the main control unit (10), indicating that the execution is finished. During the playback of the sounds, the main control unit (10) can send additional commands, such as stopping, canceling, or repeating the command, to the voice command unit (17), ensuring that the operator receives appropriate voice feedback. All communications between the main control unit and the voice command unit (17), as described above, are carried out via the CANBUS protocol.

[0047] The voice command unit (17) is in constant communication with the main control unit (10). When the main control unit (10) limits the operator's actions, it transmits information about safe movements and sections requiring operator warning or notification to the voice command unit (17) via the CANBUS line. The voice command unit retrieves the corresponding pre-recorded and predefined sounds from its memory and audibly communicates the commands to the operator. During this process, if the operator performs the correct action, the machine returns to operation within its capacity, and the main control unit (10) permits the machine movements (11). However, if the operator attempts an incorrect action, the main control unit (10) detects this and sends the relevant warnings and commands back to the voice command unit (17). In this way, the operator is guided through voice commands without needing to look at a screen until the machine is safely returned to proper operational conditions. The memory in the main control unit (10) records instances of incorrect usage and operations exceeding capacity. The operational status is communicated to relevant parties, such as the machine owner or occupational safety specialists, through the GSM / GPS module (18), which sends alerts and the machine's location to their mobile phones.

Claims

CLAIMS1. A voice-guided moment control assistant for industrial machines with hydraulic arms, designed to guide the operator based on signals sent by a main control unit (10) in which all possible approved and disapproved joint movements are recorded and generates corresponding signals during operation, characterized by comprising:- A memory unit containing a voice command database with pre-matched voice files corresponding to each potential signal,- A signal detector capable of identifying the type of signals generated by the main control unit (10) for all joint movements that can be executed by a machine operator and matching them with the corresponding voice in the database, and- A speaker for delivering the matched voice commands to the operator.

2. The signal detector according to Claim 1, characterized by being a processor.

3. The voice-guided moment control assistant according to Claim 1 , characterized by comprising a CANBUS protocol.

4. The voice-guided moment control assistant described in Claim 3, characterized by comprising an interface accessible via a mobile device that allows configuring which signals in the memory unit are matched with which voice files.

5. The voice-guided moment control assistant described in Claim 1 , characterized by comprising a signal detector capable of sequentially detecting signals generated by the main control unit (10) to guide the operator through at least two consecutive actions required to reach the safe operating zone.

6. The voice-guided moment control assistant described in Claim 1 , characterized by comprising a signal detector capable of identifying the number of times the signals generated by the main control unit (10) should be played to guide the operator to the safe operating zone.

7. The voice-guided moment control assistant described in Claim 1 , characterized by the signals generated by the main control unit (10) containing information about the sequence of actions and the number of repetitions required.

8. The voice-guided moment control assistant described in any of the preceding claims, characterized by comprising the voice command unit (17) that sendsfeedback confirming the receipt of signals from the main control unit (10) after receiving them.

9. The voice-guided moment control assistant described in any of the preceding claims, characterized by comprising a voice command unit (17) that sends feedback confirming the completion of actions corresponding to the signals sent by the main control unit (10) after the actions are performed.

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