Continuous Grade Control Calibration Using Vision-Based Implement Measurement
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Solution Overview
Problem
Conventional earthmoving machines require manual and time-consuming calibration of grade control systems due to wear in ground-engaging implements, leading to inaccurate positioning and costly maintenance.
Innovation Solution
A grade control calibration system with a vision processing system and imaging devices to continuously measure and calibrate the position of cutting portions of work implements using 3D point clouds and machine learning algorithms, eliminating the need for manual updates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual calibration is performed at certain intervals, then the grade control system can be updated with new implement dimensions, but the process is tedious, time consuming, and costly
Solution Approach 1:
The system uses the work machine's own imaging devices to automatically measure cutting portion dimensions and update the grade control system without requiring external manual measurement. The vision processing system captures images of the cutting portions and autonomously calculates dimensions, eliminating the need for operators to perform manual calibration activities.
Solution Approach 2:
The patent replaces manual mechanical measurement with an automated vision processing system that uses imaging devices and computer vision algorithms to measure cutting portion dimensions. This substitution eliminates manual calibration activities and automatically updates the grade control system with current implement dimensions.
2Reliability
If manual calibration is performed at certain intervals, then implement wear can be accounted for, but the frequency must be increased to maintain accuracy, increasing maintenance costs
Solution Approach 1:
The system continuously monitors cutting portion dimensions by capturing images at regular operational intervals and automatically updating the grade control system. This continuous calibration approach ensures grading accuracy is maintained without requiring frequent manual intervention, as the system adapts to wear in real-time during normal operation.
Solution Approach 2:
The vision processing system provides continuous feedback on cutting portion dimensions to the grade control system. By regularly capturing images and measuring current dimensions, the system automatically adjusts implement positioning calculations to account for wear, maintaining grading accuracy without manual recalibration events.
3Extent of automation
If the imaging device captures images of cutting portions, then the length can be measured, but the system complexity increases
Solution Approach 1:
The imaging devices that capture images of cutting portions are existing components already present on the work machine for other operational purposes. By repurposing these existing devices for calibration functions, the system achieves automation without adding significant hardware complexity, as the same imaging infrastructure serves multiple functions.
Solution Approach 2:
The system creates a digital representation (copy) of the cutting portions through image capture and processes this digital information to determine dimensions. This copying approach replaces physical manual measurement with digital processing, achieving automation while maintaining manageable system complexity through software-based measurement algorithms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables continuous, accurate, and cost-effective calibration of grade control systems, reducing time and effort in maintaining precise implement positioning during grading operations.
Implementation Method 1
an imaging device fixed to the linkage assembly and configured to generate a three-dimensional point cloud of a cutting portion of the work implement
Data Source
AI summary
A work machine includes a frame, a linkage assembly, a work implement connected to the linkage assembly, and a grade control calibration system. The grade control calibration system includes a vision processing system, which includes a sensor fixed to the linkage assembly and a first controller. The vision processing system is configured to measure a length of a cutting portion of the work implement, and to transmit the length of the cutting portion of the work implement. The grade control calibration system also includes a grade control system in communication with the vision processing system and the linkage assembly. The grade control system includes a second controller configured to receive the length of the cutting portion of the work implement from the first controller, and to calibrate a position of the work implement based on the received length of the cutting portion of the work implement.