Dynamic Bucket Control Profile for Mining Loader
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Solution Overview
Problem
Existing loading systems for work machines, such as mining vehicles, face inefficiencies in loading material from stacks due to inadequate control over the bucket and boom positions, leading to issues like high resistance and slow movement, which can result in incomplete loading and increased operational costs.
Innovation Solution
A method and apparatus that select a control profile based on distance traveled and real-time conditions, allowing for dynamic adjustment of bucket and boom positions to optimize loading efficiency by switching between predefined control profiles or using offset values to adjust positions, ensuring effective material collection and transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the loading equipment drives forward with large force to load material from the stack, then the loading speed increases, but the resistance from the material stack causes the equipment to stop and requires bucket lifting, reducing loading efficiency
Solution Approach 1:
The control system dynamically adjusts the bucket and boom positions based on real-time loading conditions and pre-defined control profiles. Instead of static positioning, the system continuously modifies the geometry of the bucket assembly relative to the material stack, optimizing the loading angle and force application point to maintain forward motion while reducing stopping events
Solution Approach 2:
The system changes geometric parameters (bucket angle, boom elevation, horizontal distance from stack) based on loading progress and resistance feedback. By adjusting these parameters according to control profiles, the system optimizes the mechanical advantage and reduces resistance forces while maintaining loading speed
2Productivity
If the bucket is lifted frequently to overcome resistance during loading, then the equipment can continue moving forward, but the loading process becomes interrupted and less efficient
Solution Approach 1:
The control system pre-defines optimal bucket and boom positions in control profiles before loading begins. By anticipating resistance conditions based on loading depth and position, the system proactively adjusts geometry to prevent stopping, eliminating the need for reactive bucket lifting
Solution Approach 2:
The system monitors loading conditions and uses feedback to determine when to adjust bucket and boom positions. This closed-loop control prevents resistance buildup that would require interruption, maintaining continuous forward motion by making real-time geometric adjustments
3Device complexity
If fixed control profiles are used for bucket and boom positions, then the control system is simple, but it cannot adapt to varying loading conditions and material properties
Solution Approach 1:
While maintaining a structured control profile framework, the system dynamically selects and adjusts profiles based on detected loading conditions. The control profiles are not rigid but can be modified in real-time, allowing adaptation to different material types, stack densities, and loading scenarios without requiring completely complex adaptive algorithms
Solution Approach 2:
The control system divides the loading process into segments with different control profiles optimized for specific phases (approach, initial loading, deep loading, completion). This segmentation allows simple, pre-programmed control for each phase while adapting the sequence and parameters of profiles based on overall loading conditions
Data Source
AI summary
A method for controlling loading material to a bucket of a work machine from a stack of material is disclosed. The method includes the steps: of selecting a control profile to be used as a basic control profile including indications for positions of at least one of the bucket and the boom of the work machine as a function of a distance traveled by the work machine with reference to a reference location; obtaining information of a distance traveled by the work machine while loading material to the bucket; examining at least one condition regarding the work machine during loading; and determining, on the basis of the examined condition, whether another position than indicated by the selected control profile is to be used for at least one of the bucket and the boom.