Autonomous Edge Dumping Control System for High-Wall Operations
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Solution Overview
Problem
Existing autonomous machine control systems for high-wall operations are inefficient due to complex computations and failure to account for irregularities in berm contours, leading to material being dumped inside the berm or against it, resulting in decreased productivity and increased costs.
Innovation Solution
A control system comprising a communicating device, a locating device, a sensor, and onboard and offboard controllers that generate and adjust dump target coordinates in real-time based on machine position and contact with the berm, ensuring accurate dumping by validating dump target locations and adjusting trajectories to prevent berm impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the smoothing operation is used to create the continuous curve, then the trajectory is continuous, but the computational complexity increases and control is delayed
Solution Approach 1:
The patent extracts the complex smoothing operation from the control system and replaces it with a simpler trajectory generation method that directly calculates dump target locations based on berm survey data and machine position, eliminating the need for computationally intensive curve smoothing while maintaining trajectory continuity
Solution Approach 2:
The system performs preliminary actions by pre-calculating and storing berm contour data and survey information before the dumping operation begins. This allows the control system to quickly determine dump targets using simple lookups and basic calculations rather than performing complex real-time computations
2Manufacturing precision
If the dump target is always located a predetermined distance away from the curve, then the positioning is consistent, but the irregularities in berm contour are not accounted for
Solution Approach 1:
The patent implements dynamic positioning by continuously adjusting the dump target location based on the machine's current position and the actual berm contour geometry. The system calculates the optimal dump target at each position along the trajectory, allowing the target location to dynamically adapt to berm irregularities rather than maintaining a fixed offset distance
Solution Approach 2:
The system uses feedback from the machine's locating device and sensor data about the berm contour to continuously adjust and recalculate the dump target position. This closed-loop approach ensures that the dump target accurately reflects the actual berm geometry at each position, improving both precision and adaptability
3Manufacturing precision
If the machine continues to the predetermined dump target, then the dumping location is accurate, but the machine may bump into the berm or dump inside it
Solution Approach 1:
The system performs preliminary validation of the dump target location by checking whether the calculated target position falls within the acceptable dumping zone and maintains proper clearance from the berm. If the target is invalid (e.g., would cause bumping or dumping inside the berm), the system recalculates an alternative target position before the machine arrives, preventing harmful contact
Data Source
AI summary
A control system is disclosed for use with a machine. The control system may have a communicating device, a locating device configured to generate a first signal indicative of a location of the machine, a sensor configured to generate a second signal indicative of contact of the machine with a berm, and an onboard controller. The control system may also have an offboard controller configured to generate a first set of coordinates of a dump target, and to assign the first set of coordinates to the onboard controller for use in controlling the machine. The offboard controller may also be configured to detect contact of the machine with the berm based on the second signal during reverse travel toward the dump target, and to generate a second set of coordinates of the dump target to correspond with a location of the machine at a time of contact detection.