Excavator Bucket Load Determination via Optical Distance Matrix
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing weight determination methods for construction machines, such as excavators, are inaccurate due to complex dynamic movements and varying material properties like density and humidity, leading to inefficiencies in loading and volume estimation.
Innovation Solution
A noncontact distance measuring device, such as a camera or distance-measuring apparatus, is used to directly determine the filling volume of the excavator bucket by measuring distances and creating a matrix of distance values, allowing for precise volume calculations and integration with weight measurements to derive accurate load information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If weight determination is carried out via motor power measurement, then weight values can be obtained during loading, but the measurement accuracy is poor due to complex dynamic movements and inertial forces
Solution Approach 1:
The patent replaces the mechanical power measurement system with an optical measurement system. A camera records the bucket filling process, and image processing algorithms calculate the volume of material in the bucket. This substitution eliminates the need to measure motor power and compensate for dynamic forces, providing direct and accurate volume measurement without the complexities of mechanical sensing.
Solution Approach 2:
The patent creates a visual copy (image) of the bucket and its contents using a camera. By capturing images from multiple angles and processing them computationally, the system generates an accurate representation of the material volume. This copying approach allows volume determination without physical contact or mechanical interference with the loading process.
2Measurement precision
If multiple sensors and central control are used for position measurement, then bucket position can be determined accurately, but the setup becomes very complicated and fault-prone
Solution Approach 1:
The camera serves multiple functions: it records the bucket position, captures the material volume, and provides data for both volume calculation and position determination. This multi-functional approach replaces the need for separate position sensors and central control systems, simplifying the overall system while maintaining measurement accuracy and improving reliability through fewer components.
3Measurement precision
If weight-based volume estimation is used, then volume can be calculated from weight measurements, but accuracy is reduced due to varying material properties like density and humidity
Solution Approach 1:
The patent replaces weight-based estimation with direct optical volume measurement. By using image processing to calculate the actual volume of material in the bucket, the system eliminates the need to account for varying material properties such as density and humidity. This direct measurement approach provides accurate volume data regardless of material composition changes.
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
This method provides accurate and real-time load measurements with minimal effort, enabling precise volume determination and improved loading efficiency by accounting for material properties, reducing errors in weight-based volume estimates.
Implementation Method 1
A noncontact distance measuring device, such as a camera or distance-measuring apparatus, is used to directly determine the filling volume of the excavator bucket by measuring distances
Data Source
AI summary
For determining the load of an excavator bucket, or optionally of another holding region, a measurement step and an evaluation step are carried out. In the measurement step, the position of a load surface is determined by a noncontact distance-measuring device and, in the evaluation step, a load volume is determined from the position of the load surface and the position and shape of the excavator bucket or of the holding region. For determining the position of the load surface, at least one two-dimensional matrix with distance values is created by means of a distance-measuring camera. For determining the position of the excavator bucket, the distances to at least three points of the excavator bucket, in particular to points on the upper bucket edge, optionally to marked points are determined using the distance-measuring apparatus for determining the surface.