Construction Machine Self-Calibration Controller
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Solution Overview
Problem
Current calibration methods for construction machines, such as hydraulic excavators, require expensive external measuring devices and specialized expertise, limiting their usability and accuracy, especially when installed at construction sites.
Innovation Solution
A self-calibration system for construction machines that includes angle sensors, a controller with angle computing and work point position calculation sections, and a calibration value computing section, allowing operators to easily calibrate the machine by positioning the work point on a datum line and updating parameters to maintain accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external measuring devices are used for calibration, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The construction machine performs self-calibration using its own work implement and angle sensors without requiring external measuring devices. The calibration controller computes calibration values by detecting angles when the work point is positioned on a datum line, enabling the system to calibrate itself autonomously.
Solution Approach 2:
Instead of using expensive external measuring devices, the system creates a virtual copy of the measurement function through computational geometry. The calibration controller calculates calibration values based on angular measurements and geometric relationships, replicating the measurement capability software-based rather than hardware-based.
2Measurement precision
If external measuring devices are used for calibration, then measurement precision is improved, but ease of operation deteriorates
Solution Approach 1:
The system eliminates the need for specialized external devices and expert knowledge by enabling operators to perform calibration using the machine's own sensors and a simple datum line reference. The calibration controller automatically processes the angular measurements and computes calibration values without requiring manual measurement or expert intervention.
Solution Approach 2:
The patent replaces mechanical external measuring devices with an electronic/computational system. The calibration controller uses angle sensor outputs and geometric calculations to determine calibration values, substituting physical measurement tools with electronic sensing and software-based computation.
3Measurement precision
If external measuring devices are used for calibration, then measurement precision is improved, but adaptability deteriorates
Solution Approach 1:
The construction machine uses its own angle sensors and computational controller to perform calibration autonomously at any construction site without requiring external measuring devices. This self-calibration capability enables deployment in diverse locations including remote sites where external equipment cannot be transported or set up.
Solution Approach 2:
The system replicates the measurement function through computational methods using existing onboard sensors. By calculating calibration values from angular measurements and geometric relationships rather than relying on external devices, the system achieves measurement precision while maintaining adaptability to any construction site environment.
4Manufacturing precision
If traditional calibration methods are used, then manufacturing precision is maintained, but productivity deteriorates
Solution Approach 1:
The calibration process is automated through the calibration controller, which automatically processes angle sensor data and computes calibration values without requiring manual measurement or expert intervention. This self-calibration capability maintains precision while significantly reducing calibration time and operational complexity.
Solution Approach 2:
The patent replaces manual calibration procedures with an automated electronic system. The calibration controller continuously receives angle sensor inputs, performs real-time geometric calculations, and updates calibration parameters automatically, replacing time-consuming manual measurement and calculation processes with rapid electronic computation.
Data Source
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AI summary
When a work implement 3 is actuated in such a manner that a work point is located at each of a plurality of positions on a datum line, a first work point position computing section 40b calculates a position of the work point at each of the plurality of positions. A calibration value computing section 49b calculates calibration values of angle conversion parameters (αbm, βbm, αam, βam, αbk, βbk), dimension parameters (Lbm, Lam, Lbk), and line parameters (tilt tanθ, intercept Zline) using the fact that the positions of the work point at each of the plurality of positions calculated by the first work point position computing section 40b can satisfy a linear equation indicating a datum line. A parameter update section 49c reflects the calibration values calculated by the calibration value computing section 49b in computation by a corresponding computing section 40a that is one of the angle computing section and the first work point position computing section 40b.