Excavator Controller Dynamic Calibration for Soil Accuracy
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Solution Overview
Problem
Hydraulic excavators face reduced accuracy in soil excavation due to variations in operation characteristics and changing work situations such as soil hardness, fluid temperature, bucket weight, and target surface gradient, which existing calibration methods fail to address effectively in real-time.
Innovation Solution
A work machine equipped with a multi-joint implement, hydraulic actuators, and a controller that communicates with a management server to adjust control parameters based on real-time work situation parameters, allowing for dynamic correction of control commands to optimize excavation accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If calibration is performed only at factory shipment or before work site introduction, then variations in hydraulic cylinder operation characteristics are restrained, but accuracy reduction occurs when work situation changes
Solution Approach 1:
The patent implements dynamic correction of control commands by continuously monitoring work situation parameters (soil hardness, fluid temperature, bucket weight, target surface gradient) and adjusting control parameters in real-time based on detected deviations from target surface, enabling the system to adapt to changing work conditions rather than relying on static factory calibration
Solution Approach 2:
The system incorporates feedback mechanisms where the actual position of the front work implement is continuously monitored against the target surface, and control commands are corrected based on the detected deviation, creating a closed-loop control system that maintains accuracy despite variations in operation characteristics and changing work situations
2Reliability
If control parameters are corrected for each work situation using adjustment tools, then excavation accuracy is improved, but time is consumed for accuracy adjustment
Solution Approach 1:
The system performs self-correction of control parameters by automatically detecting work situation parameters and computing corrected control commands based on detected deviations from target surface, eliminating the need for manual intervention with adjustment tools and enabling continuous automatic adaptation to changing conditions
3Measurement precision
If factory calibration is performed to restrain accuracy reduction, then individual machine variations are compensated, but real-time adaptation to work environment changes is not achieved
Solution Approach 1:
The system pre-stores multiple sets of control parameters corresponding to different work situations (soil hardness, fluid temperature, bucket weight, target surface gradient), and automatically selects and applies the appropriate parameter set based on currently detected work conditions, enabling rapid adaptation without manual reconfiguration
Data Source
AI summary
A controller 20 mounted on a hydraulic excavator 1 that is able to perform machine control transmits work situation parameters (machine body position, hydraulic working fluid temperature, bucket weight, and target surface gradient) to a management server 71, receives, from the management server, control command correction values that are calculated by the management server on the basis of the work situation parameters and that represent correction values for correcting control commands, and controls hydraulic actuators 5, 6, and 7 with corrected control commands that represent the control commands corrected on the basis of the control command correction values.