Camera-Based Blade Marker Calibration for Grade Control
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Solution Overview
Problem
Current grade control systems for work vehicles, such as crawlers and motor graders, require time-consuming and labor-intensive calibration processes, leading to operational downtime and accuracy issues due to wear and tear, making it difficult to maintain precise blade tip positioning and achieve desired slope and elevation targets.
Innovation Solution
A camera system is integrated into the work vehicle to measure the location of blade markers on the rear face of the blade, allowing for real-time calibration of the grade control system by capturing images of markers at specific cylinder configurations, enabling continuous operation and accounting for wear over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional manual calibration methods (tape measure, plumb bob, T-square) are used to calibrate the grade control system, then measurement accuracy can be achieved, but the calibration process is time-consuming and causes operational downtime
Solution Approach 1:
The patent replaces manual mechanical measurement tools (tape measure, plumb bob, T-square) with an automated optical measurement system consisting of a camera mounted on the vehicle and markers attached to the blade. The camera captures images of the markers to automatically determine blade position, eliminating the need for manual measurements and significantly reducing calibration time while maintaining or improving accuracy.
Solution Approach 2:
The patent uses visual markers (targets) attached to the blade that create a measurable optical copy of the blade's position. Instead of directly measuring the blade tip with physical tools, the system captures an image of the marker and uses image processing to determine position, effectively creating a measurable representation of the blade's spatial coordinates.
2Measurement precision
If frequent recalibration is performed to account for track wear and maintain accuracy, then grading precision is maintained, but operational downtime increases
Solution Approach 1:
The patent enables continuous operation by making calibration a quick, automated process that can be performed rapidly without shutting down the vehicle. The camera-based system allows calibration to be completed in minutes rather than hours, and the system can be recalibrated frequently as needed to account for track wear while minimizing disruption to productive work.
Solution Approach 2:
The calibration system is self-calibrating in the sense that it automatically processes images and calculates blade position without requiring operator intervention for manual measurements. The system performs its own calibration function through automated image capture and processing, reducing the skill level and time required for calibration operations.
3Adaptability or versatility
If manual calibration procedures are used for complex vehicles like motor graders with multiple adjustable blade positions, then calibration can be performed, but the complexity of the calibration process increases significantly
Solution Approach 1:
The patent attaches markers to the blade that serve as visual copies of the blade's position and orientation. The camera captures these markers and image processing algorithms automatically determine the blade's spatial coordinates, eliminating the need for complex manual measurements across multiple adjustment dimensions. This works regardless of how many times the blade is rotated, tilted, or positioned.
Solution Approach 2:
The patent replaces complex manual measurement procedures with an automated optical measurement system. Instead of using multiple physical tools to measure various blade positions and orientations, a single camera captures images of markers that automatically encode the blade's position information, simplifying the calibration process for vehicles with multiple degrees of freedom.
Data Source
AI summary
A system includes calibrating a grade control system of a work vehicle having a controller operatively connected to a camera. A plurality of cylinders operative to move a blade on the vehicle. The blade includes one or more blade markers. One of the cylinders moves to a predetermined configuration that is between 0% and 100% of maximum stroke length, and the camera takes a corresponding image of the one or more blade markers. The controller measures a corresponding location of the one or more blade markers using the corresponding image and calibrates the grade control system based on the corresponding location of the one or more blade markers. The stored corresponding location can be an initial calibration location or a corresponding calibration location that was previously determined during operating conditions of the work vehicle. The grade control system is calibrated in real-time while the work vehicle is operating or stationary.