Autonomous Machine Double Cut Control for Terrain Stability

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Solution Overview

Problem

Autonomous and semi-autonomous machines operating in environments with varying terrain face challenges in accurately navigating between slots of different elevations, risking tipping over or becoming buried in material, especially when the machine fails to follow the path and enters a berm between slots.

Innovation Solution

A system and method utilizing a position sensor and controller to determine topography, maximum cutting and carrying capacities, and generate commands for double cut operations to manage material movement efficiently, ensuring the machine moves material in a way that avoids excessive cutting or carrying capacity, thereby preventing accidents and improving operational efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the machine operates in autonomous or semi-autonomous manner to maintain consistent productivity, then productivity is improved, but the risk of tipping over or becoming buried in material increases due to inaccurate path following between slots of different elevations

Engineering Contradiction:

Improveconsistent productivityVSAvoidrisk of tipping over or becoming buried

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system continuously receives real-time position data from multiple GPS receivers and compares the actual machine position against the planned path. The controller automatically adjusts steering and positioning commands based on this feedback to maintain accurate path following between slots of different elevations, thereby preventing tipping or burial while maintaining autonomous productivity

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces manual operator control with an automated control system that uses GPS positioning, topographic data processing, and computer-generated steering commands. This substitution of mechanical/manual control with electronic automation enables consistent autonomous operation while maintaining precision through digital path following rather than human judgment

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If the machine cuts deeper to increase material removal rate, then productivity is improved, but the cutting capacity is exceeded causing operational failures

Engineering Contradiction:

Improvematerial removal rateVSAvoidcutting capacity limitation

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system dynamically adjusts cut depth and loading profile based on real-time topographic data and machine capacity parameters. The controller continuously calculates optimal cutting parameters that maximize material removal while staying within the machine's cutting capacity limits, adapting to varying terrain conditions rather than using fixed deep-cut parameters

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent changes operational parameters (cut depth, speed, loading profile) based on calculated topographic features and machine capacity. The system optimizes these parameters to achieve maximum productivity within safety limits, adjusting the cutting regime dynamically rather than operating at constant maximum depth

Inventive Principle:

Principle #35Parameter changes

3Productivity

If the machine carries more material to reduce trips, then productivity is improved, but the carrying capacity is exceeded causing instability

Engineering Contradiction:

Improvereduced tripsVSAvoidcarrying capacity limitation

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system optimizes material loading to approach but not exceed carrying capacity limits. By carefully calculating the maximum safe load based on terrain and machine parameters, the system achieves near-maximum loading that minimizes trips while maintaining stability, avoiding both underloading and overloading extremes

Inventive Principle:

Principle #16Partial or excessive action

4Reliability

If the machine follows a precise path between slots to avoid berms, then safety is improved, but the complexity of path control increases

Engineering Contradiction:

Improvesafety from tipping or burialVSAvoidpath control complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent introduces an automated control system as an intermediary between the operator and the machine. This intermediary processes topographic data, calculates safe paths between slots of different elevations, and automatically executes steering commands, thereby managing the complexity of precise path following without requiring direct operator intervention

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS10774506B2System and method for controlling the operation of a machine

Publication Date: 2020.09.15 CATERPILLAR INC

AI summary

A system for moving material with a ground engaging work implement determines a topography of the work surface, a maximum cutting capacity for a cutting operation, and a maximum carrying capacity for a carrying operation. A first double cut location is determined based upon the maximum carrying capacity and the topography of the work surface and a second double cut location is determined based upon the maximum carrying capacity and a modified topography of the work surface. Individually, the amount of material from each of the first and second double cut locations is less than the maximum cutting capacity, and combined is less than the maximum carrying capacity. A first forward double cut command moves the first double cut material to an intermediate position and a second forward double cut command moves the first double cut material and the second double cut amount of material to a dump location.