Excavating Machine Bucket Mass Calculation via Rope Force
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Solution Overview
Problem
Existing methods for accurately calculating the mass of material in excavating machine buckets, such as those used in large-scale mining, suffer from inaccuracies and require complex, expensive equipment, making them unsuitable for autonomous truck fleets.
Innovation Solution
A method and system that utilizes a controller to calculate the mass of material in an excavating machine bucket by receiving data from sensors and torque measurements, determining frontend geometry, and calculating rope force, without the need for battery-powered loadcells and telemetry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If electrical parameter methods are used to calculate bucket load, then the system complexity is reduced, but the measurement precision deteriorates with variations of twenty to thirty percent
Solution Approach 1:
The patent combines multiple measurement approaches by integrating strain gauge data from the A-frame legs with suspension cable force measurements. This hybrid method merges the advantages of both electrical parameter sensing and mechanical force measurement to achieve improved precision while maintaining reasonable system complexity.
Solution Approach 2:
The patent employs a composite measurement system that integrates multiple sensing technologies (strain gauges, force sensors) rather than relying on a single method. This composite approach combines the reliability of mechanical measurements with the data processing capabilities of electrical sensing to overcome the limitations of individual methods.
2Measurement precision
If hybrid structural methods with strain gauges on A-frame legs are used, then the measurement precision improves to within fifteen percent, but the device complexity and calibration difficulty increase
Solution Approach 1:
The patent extracts the critical measurement function to the suspension cable force measurement, which directly reflects the bucket load. By measuring the force in the suspension cable rather than inferring it from multiple structural points, the system achieves high precision while simplifying the overall measurement architecture and reducing calibration complexity.
3Measurement precision
If loadcells with battery power and telemetry are deployed, then the measurement precision reaches within five percent accuracy, but the device complexity and maintenance requirements increase significantly
Solution Approach 1:
The patent employs measurement systems that utilize the existing structural elements and power sources of the excavating machine itself. The strain gauges and force sensors are powered by the machine's existing electrical system and integrate with its control architecture, eliminating the need for separate battery packs and telemetry systems while maintaining high measurement accuracy.
Data Source
AI summary
An aspect of the present disclosure provides a method for calculating the mass of material in an excavating machine bucket including receiving, by a controller, data for determining the distance between at least one sensor mounted on the excavating machine and a target positioned on an arm of the excavating machine. Moreover, the method includes receiving torque data for a rotating hoist drive shaft in the excavating machine. The torque data is generated by a torque sensor positioned about the shaft. Furthermore, the method includes calculating frontend geometry of the excavating machine. The excavating machine includes at least one rope. Additionally, the method includes calculating a rope force in the at least one rope using the torque data and calculating the mass of material in the excavating machine bucket using the calculated frontend geometry and the rope force.