Adaptive Grade Control System for Work Machines
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Solution Overview
Problem
Laser grading systems in work machines can be disrupted by external objects, leading to communication breakdowns between the laser beacon and receiver, which affects the accuracy and continuity of grade control during grading operations.
Innovation Solution
An adaptive control system that includes sensors to measure angles relative to gravity, a laser receiver to generate height signals for maintaining attachment positions, and a controller to generate control signals for actuators, ensuring the attachment maintains the target grade even in the absence of laser signals by using historical grade profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If laser grading systems are used for grade control, then grading precision is improved, but communication reliability deteriorates when objects disrupt laser signals
Solution Approach 1:
The system introduces alternative intermediary sensors (inertial sensors, GPS receivers, depth sounders) that can mediate the measurement function when the primary laser communication intermediary is disrupted. These sensors provide alternative pathways for obtaining grade control data, ensuring continuity when laser signals are blocked.
Solution Approach 2:
The system dynamically changes the measurement parameters by switching between different sensor types and data sources based on signal availability. When laser signals are disrupted, the system transitions to using inertial measurement unit data, GPS elevation data, or depth sounder measurements, effectively changing the physical parameters used for grade control.
2Productivity
If the system switches to historical grade profiles when laser signals are lost, then operational continuity is improved, but grading precision deteriorates
Solution Approach 1:
The system prepares historical grade profile data and alternative sensor data beforehand to cushion against laser signal disruptions. By having pre-stored reference data and alternative measurement capabilities ready, the system can maintain operations during signal loss without immediate precision degradation, then reconcile data when signals are restored.
Solution Approach 2:
The system implements feedback mechanisms that continuously monitor laser signal quality and automatically trigger transitions to alternative data sources when degradation is detected. This feedback loop ensures smooth transitions and allows the system to switch back to laser data when restored, maintaining precision through continuous validation against target grade specifications.
3Reliability
If multiple sensors are integrated for redundancy, then system reliability is improved, but device complexity increases
Solution Approach 1:
The system integrates multiple sensors that serve universal purposes - the inertial measurement unit provides both orientation data for laser alignment and standalone grade measurement capability, while GPS provides both location tracking and elevation reference. This multi-functionality reduces the need for completely separate redundant systems, managing complexity through shared components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system ensures continuous and accurate grading operations by maintaining attachment positions based on target grades and historical profiles, reducing the need for operator intervention and minimizing disruptions from equipment failures.
Implementation Method 1
The laser receiver is configured to receive a laser signal from a laser beacon
Implementation Method 2
The first sensor is configured to generate a first sensor signal indicative of an angle of the frame relative to the direction of gravity
Implementation Method 3
The second sensor is configured to generate a second sensor signal indicative of an angle of the ground-engaging attachment relative to one of the frame and the direction of gravity
Data Source
AI summary
An adaptive control system automatically controls an attachment position during a grading operation of a surface. The system comprises a frame, an attachment, first sensor, a second sensor, a laser receiver and a controller. The first sensor generates a first sensor signal indicative of an angle of the frame. The second sensor generates a second sensor signal indicative of an angle of the ground-engaging attachment. The laser receiver receives a laser signal from a laser beacon and generates a height signal based on the laser signal. The height signal is indicative of a position of either the attachment or the frame relative to the laser signal. The controller establishes a target grade based on a desired grade of the surface; identifies a position of the attachment; receives the first sensor signal; the second sensor signal; and the laser signal. The controller generates a first control signal or second control signal based on the inputs.