Dynamic Carryback Threshold Management in Surface Haulage

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Solution Overview

Problem

Carryback material in haul trucks reduces machine productivity and fuel efficiency by decreasing the effective capacity of the dump body and increasing the number of haul cycles required, leading to increased operational costs.

Innovation Solution

A machine routing and planning system that monitors carryback thresholds in haul trucks, generates movement plans, and schedules clean-out operations to minimize carryback material, optimizing the number of haul trucks and loading machines based on real-time data to maintain efficient material movement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If carryback material is allowed to accumulate in the dump body, then the number of clean-out operations is reduced, but the effective capacity of the dump body decreases and fuel efficiency worsens

Engineering Contradiction:

Improvenumber of haul cyclesVSAvoidfuel efficiency

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The system dynamically adjusts the carryback threshold parameter based on the number of loading machines and haul trucks operating at the work site. When fewer haul trucks are available, the threshold is increased to allow more carryback material, reducing clean-out frequency and maintaining productivity. When more trucks are available, the threshold is decreased to maintain lower carryback levels and improve fuel efficiency.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The carryback threshold is not a fixed value but a dynamic parameter that changes in response to real-time fleet conditions. The controller continuously monitors the number of operating haul trucks and loading machines, and automatically adjusts the threshold to optimize the balance between productivity and fuel efficiency under varying operational conditions.

Inventive Principle:

Principle #15Dynamics

2Use of energy by moving object

If the carryback threshold is lowered to reduce carryback material, then fuel efficiency improves, but the number of clean-out operations increases and productivity decreases

Engineering Contradiction:

Improvefuel efficiencyVSAvoidnumber of haul cycles

Core Design Contradiction:

Use of energy by moving objectVSProductivity

Solution Approach 1:

The system modifies the carryback threshold parameter based on real-time fleet availability. When the number of haul trucks increases, the threshold is lowered to reduce carryback material accumulation, improving fuel efficiency. When fleet size decreases, the threshold is raised to minimize clean-out operations and maintain productivity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The controller receives feedback on the number of operating loading machines and haul trucks, and uses this information to automatically adjust the carryback threshold. This closed-loop control ensures the threshold is optimized for current operational conditions, balancing fuel efficiency and productivity requirements.

Inventive Principle:

Principle #23Feedback

3Productivity

If more haul trucks are deployed to maintain productivity, then the number of haul cycles increases, but the complexity of fleet management and operational coordination increases

Engineering Contradiction:

Improvematerial movement efficiencyVSAvoidfleet management complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system automatically monitors the number of operating machines, determines optimal carryback thresholds, generates material movement plans, and issues command signals without human intervention. This self-service capability eliminates the need for complex manual fleet coordination, allowing the system to efficiently manage varying fleet sizes through automated decision-making.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual fleet management and coordination with an automated control system that uses electronic monitoring and communication. The controller automatically tracks machine availability, calculates optimal thresholds, and directs operations, substituting complex human coordination with automated electronic control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS10968602B2System and method for managing carryback thresholds in surface haulage

Publication Date: 2021.04.06 CATERPILLAR INC

AI summary

A machine routing and planning system for mobile machines at a work site includes a plurality of haul trucks, at least one loading machine, and a controller. The controller is configured to generate an initial material movement plan based upon an initial number of loading machines and haul trucks and the initial carryback threshold, and generate initial movement command signals to operate the loading machines and haul trucks at the work site based upon the initial material movement plan. The controller is further configured to generate a modified material movement plan based upon a modified number of loading machines and haul trucks and the modified carryback threshold, and generate modified movement command signals to operate the loading machines and haul trucks at the work site based upon the modified material movement plan.