Inline Blade Wear Estimation for Soil Processing Implements

Solution Overview

Problem

Existing construction vehicles face challenges in maintaining precise soil processing due to wear and shape deviations of the implement's cutting edges, leading to inefficient operations and potential damage.

Innovation Solution

A method and system that utilize a computing unit, positioning sensor, implement tracking sensor, and visual perception sensor to derive the wear state of the soil interaction component by comparing actual 3D surface models with expected models, allowing for real-time adjustments and maintenance optimization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the implement operates continuously without replacement, then productivity is improved, but manufacturing precision deteriorates due to wear and shape deviations

Engineering Contradiction:

Improvecontinuous operation timeVSAvoidsoil processing precision

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system performs preliminary wear detection by continuously monitoring the implement's geometry and comparing it against reference data. This early detection allows for proactive maintenance scheduling before precision is significantly compromised, enabling continuous operation while maintaining quality standards through planned interventions rather than reactive replacements.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system establishes a closed-loop feedback mechanism where wear state information is continuously fed back to the control system. This feedback enables real-time adjustment of operating parameters or alerting operators to schedule maintenance, thus extending productive operation while preventing precision degradation beyond acceptable thresholds.

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If the implement is replaced frequently, then manufacturing precision is improved, but productivity deteriorates due to downtime

Engineering Contradiction:

Improvesoil processing precisionVSAvoidoperational continuity

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The system performs preliminary wear detection by continuously monitoring the implement's geometry and comparing it against reference data. This early detection allows for proactive maintenance scheduling before precision is significantly compromised, enabling continuous operation while maintaining quality standards through planned interventions rather than reactive replacements.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system establishes a closed-loop feedback mechanism where wear state information is continuously fed back to the control system. This feedback enables real-time adjustment of operating parameters or alerting operators to schedule maintenance, thus extending productive operation while preventing precision degradation beyond acceptable thresholds.

Inventive Principle:

Principle #23Feedback

3Manufacturing precision

If wear monitoring is implemented, then manufacturing precision is improved through compensation, but device complexity increases

Engineering Contradiction:

Improvewear compensation accuracyVSAvoidmonitoring system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system replaces complex mechanical measurement devices with optical or sensor-based detection methods. By using cameras, lasers, or other non-contact sensing technologies to monitor implement geometry, the system achieves high-precision wear detection without the mechanical complexity and maintenance burden of traditional dial indicators or laser scanners physically attached to the implement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system creates digital copies or 3D models of the implement's geometry at various wear stages. These digital twins are compared against the original reference model to detect wear patterns. This copying approach simplifies the physical system while enabling sophisticated wear analysis through software-based comparison algorithms.

Inventive Principle:

Principle #26Copying

Data Source

PatentEP4403712B1Inline blade wear estimation based on the processed soil surface

Publication Date: 2025.06.18 LEICA GEOSYST TECH

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AI summary

The present invention relates to a method for deriving a wear state of a soil interaction component of a soil processing implement of a construction vehicle,. The method comprises steps of 1.) providing a geometry model regarding an assumed shape of the soil interaction component, 2.) engaging the soil by using the soil interaction component and tracking a motion for deriving tracking data of the soil interaction component, 3.) using the tracking data and the geometry model to derive an expected 3D surface model, 4.) providing visual 3D perception data of a soil area affected by the engaging, such that the visual 3D perception data and the expected 3D surface model can be referenced to one another, and 5.) comparing the visual 3D perception data with the expected 3D surface model and, based thereof, determining a deviation of an effective shape of the soil interaction component from the assumed shape.