Excavator Bucket Predictive Control Across Design Surface Gradient Changes
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Solution Overview
Problem
Construction machines equipped with working equipment operated by hydraulic pressure face control delays when transitioning between surfaces with different gradients, leading to potential digging below the design surface and failure to achieve the desired construction shape.
Innovation Solution
A control system for construction machines that includes a design surface acquisition unit, a target value generation unit, a prediction unit, and a command unit, which calculates and outputs control commands to maintain the bucket's position and speed based on a prediction model, ensuring the bucket follows the design surface even across gradient changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional hydraulic control is used for working equipment, then the system structure is simple, but control delay occurs when the bucket passes through boundaries between surfaces with different gradients
Solution Approach 1:
The prediction unit calculates predicted values of control amounts in advance based on the prediction model before the bucket actually reaches the boundary between surfaces with different gradients. This allows the control system to prepare control commands proactively, eliminating the time delay that would occur with reactive control adjustments.
Solution Approach 2:
The control system dynamically adapts to changing terrain conditions by using the prediction model to anticipate future states. The control amounts are continuously updated based on predicted bucket positions and terrain gradients, allowing the system to respond smoothly to boundary transitions between surfaces with different gradients.
2Ease of operation
If conventional control is used, then the control system is simple to operate, but the bucket may fail to follow the design surface accurately
Solution Approach 1:
The control system uses feedback from the prediction model to continuously adjust control amounts. The prediction unit compares predicted bucket positions with the design surface, and the command unit generates corrected control commands to minimize deviations, ensuring accurate following of the design surface while maintaining automated operation.
Solution Approach 2:
The patent replaces conventional mechanical-hydraulic control with a predictive control system that uses calculation and information processing. The prediction model substitutes for traditional mechanical feedback mechanisms, enabling more precise control through computational methods while maintaining ease of operation through automation.
3Productivity
If the bucket speed is increased to improve productivity, then excavation efficiency improves, but control delay causes the bucket to dig below the design surface
Solution Approach 1:
The prediction unit calculates predicted control amounts in advance based on the current bucket state and terrain model, allowing the system to prepare appropriate control commands before the bucket reaches critical positions. This proactive approach enables higher bucket speeds while maintaining precision by eliminating reactive control delays.
Solution Approach 2:
The control system dynamically adjusts control amounts based on real-time predictions of bucket position and terrain conditions. This allows the bucket to move at higher speeds while the control system adapts continuously to maintain accurate following of the design surface, preventing digging below the intended elevation.
Data Source
AI summary
A control system for a construction machine includes a design surface acquisition unit configured to acquire a design surface that indicates a target shape of a construction target, a target value generation unit configured to generate a target value of an amount of control of working equipment, a prediction unit configured to calculate a predicted value of the amount of control of the working equipment based on the target value and a prediction model for the working equipment, and calculate an amount of drive to control the working equipment based on the predicted value and the design surface, and a command unit configured to output a control command for control of the working equipment based on the amount of drive.