Autonomous Loader Shovel Fill Detection During Material Loading
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Solution Overview
Problem
Autonomous loaders face challenges in efficiently loading materials from a work zone, particularly in determining when the shovel is filled with material, which affects the loading process and material transport.
Innovation Solution
An autonomous loader system comprising a speed control system, a steering control system, and a shovel control system, with a controller that uses sensor data, such as torque sensors and geolocation, to determine when the shovel is filled and adjusts its position and operation accordingly, including raising and shaking the shovel to ensure proper loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the autonomous loader uses sensor data and multiple control systems to determine when the shovel is filled, then the loading precision and reliability are improved, but the device complexity increases
Solution Approach 1:
The patent combines multiple sensing mechanisms (torque sensors, wheel slip detection, distance measurement) and control systems (speed control, steering control, shovel control) into an integrated autonomous control system. This merging allows the system to cross-validate multiple data sources to accurately determine shovel fill status, improving measurement precision while managing complexity through unified control architecture.
Solution Approach 2:
The control system performs multiple functions simultaneously: it monitors torque values, detects wheel slip, measures travel distance, controls shovel positioning, and determines fill status. This multi-functionality allows a single integrated system to handle various aspects of loading operations, improving overall system efficiency and accuracy without requiring separate dedicated systems for each function.
2Reliability
If the autonomous loader raises the shovel a predetermined amount and performs multiple checks, then the loading reliability is improved, but the loading time increases
Solution Approach 1:
The system performs a preliminary raise of the shovel by a predetermined amount after initial filling, followed by a second fill determination check. This preliminary action ensures that the shovel is properly filled and prevents material spillage during transport, improving reliability. The automated multi-check process efficiently manages the additional time required through systematic control sequencing.
3Measurement precision
If the autonomous loader uses torque sensors and wheel slip detection to determine fill status, then the measurement accuracy is improved, but the device complexity increases
Solution Approach 1:
The control system acts as an intermediary that processes data from multiple sensing mechanisms (torque sensors, wheel slip detectors, distance sensors) and synthesizes this information to determine fill status. This intermediary approach allows the system to leverage multiple measurement modalities for improved accuracy while managing sensing system complexity through centralized data processing and decision-making logic.
Data Source
AI summary
Some embodiments include an autonomous loader comprising a speed control system; a steering control system; a shovel control system; and a controller communicatively coupled with the speed control system, the steering control system, and the shovel control system. In some embodiments, the controller has code that instructs the shovel control system to place the shovel in a position to load the shovel; instructs the speed control system to move the autonomous loader into a load zone; determines whether the shovel has been filled with material from the load zone; instructs the shovel control system to raise the shovel a predetermined amount; determines a second time whether the shovel has been filled with material from the load zone; instructs the shovel control system to raise the shovel out of the load zone; and instructs the shovel control system to shake the shovel.