Excavation Load Control via Distance Feedback
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Solution Overview
Problem
Existing work machines, such as hydraulic excavators, face challenges in achieving a target excavation load due to operator variability in experience and skill, leading to inefficiencies in mineral excavation and transportation, resulting in suboptimal productivity at mining sites.
Innovation Solution
A work machine equipped with a controller that calculates excavation load based on posture and load information, determines excavation distance, and displays target excavation distances to operators, enabling them to achieve a target load value irrespective of their experience, by setting a correspondence relation between excavation load and distance using stored data and adjusting operations accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If only stop position information is provided to operators, then the system complexity is reduced, but the excavation load precision cannot be controlled accurately due to operator variability
Solution Approach 1:
The system calculates actual excavation load based on actuator load information and bucket posture, then provides feedback to the operator through the display device. This closed-loop feedback enables operators to adjust their excavation operations to achieve the target load, resolving the contradiction between precision and simplicity by using information feedback rather than complex mechanical control systems
Solution Approach 2:
The controller acts as an intermediary that processes actuator load information and bucket posture data to calculate the actual excavation load. This intermediary computation translates complex sensor data into meaningful load information that operators can use, achieving precision without requiring complex direct control mechanisms
2Productivity
If excavation operations are performed without load guidance, then the ease of operation is improved, but the productivity decreases due to overloading or underloading requiring reloading
Solution Approach 1:
The system calculates and displays the target excavation load before the operator performs the excavation operation. This preliminary information allows operators to plan their bucket extension and excavation depth in advance, achieving optimal load without trial-and-error operations that would reduce productivity
Solution Approach 2:
The display device provides real-time feedback on actual excavation load during the operation, enabling operators to make immediate adjustments to achieve the target load. This feedback mechanism maintains operational simplicity while ensuring optimal loading that prevents productivity loss from reloading
3Productivity
If the amount of loading is not controlled close to the maximum loading amount, then the ease of operation is maintained, but the capability of the transporting machine is not exerted sufficiently
Solution Approach 1:
The system provides feedback on the actual excavation load compared to the target load, enabling operators to consistently achieve optimal loading amounts that fully utilize transporting machine capability. This maintains ease of operation by using information guidance rather than complex control systems
Data Source
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AI summary
An excavation load calculated by an excavation load calculating section and an excavation distance calculated by an excavation distance calculating section are stored in a work result storage section in association with each other. A correspondence relation setting section sets correspondence relation between a target excavation load and a target excavation distance on the basis of a tendency of correspondence relation between the excavation load and the excavation distance stored in the work result storage section. The target excavation load is set on the basis of rated capacity information of a bucket. A target excavation distance calculating section calculates the target excavation distance on the basis of the correspondence relation set by the correspondence relation setting section and the target excavation load. The target excavation distance is displayed on a monitor.