Excavator Cycle Control Using Simple Position and Velocity Sensing
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Solution Overview
Problem
Current earthmoving machine control systems, particularly for excavators, lack automation of cyclical operations such as digging, lifting, carrying, dumping, and returning, relying heavily on human operators, leading to inefficiencies due to fatigue and environmental variables, and require expensive and unreliable sensors for precise control.
Innovation Solution
A system that automates cyclical operations of excavators using a simple sensor block, allowing manual override, comprising sensors for position and velocity detection, actuators for machine elements, and a controller to transmit control signals for efficient operation, with manual override options.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automatic control systems are implemented for cyclical operations, then productivity and cycle time are improved, but device complexity increases due to requirement of multiple sensors and actuators
Solution Approach 1:
The system uses the excavator's own operational data and sensor inputs to automatically control cyclical operations without requiring external complex control systems. The excavator essentially controls itself through automated decision-making based on real-time sensor feedback, reducing the need for additional complex external control infrastructure while maintaining high productivity
Solution Approach 2:
The control system is designed to handle multiple functions (digging, lifting, carrying, dumping, returning) using a unified automated control architecture. This multi-functional approach consolidates what would otherwise require separate control systems for each operation, reducing overall system complexity while improving productivity across all cyclical tasks
2Measurement precision
If expensive sensors like GPS and lasers are used for precise control, then measurement precision is improved, but cost and reliability worsen
Solution Approach 1:
The system replaces expensive, fragile sensors (GPS, lasers) with simpler, more reliable, and cost-effective sensing mechanisms. By using robust sensors that are less prone to failure and environmental damage, the system achieves sufficient measurement precision for cyclical operations while dramatically improving reliability and reducing cost
Solution Approach 2:
The system substitutes complex optical and electromagnetic sensing systems (GPS, lasers) with simpler mechanical or electrical sensing approaches that are inherently more reliable in harsh construction environments. This substitution maintains adequate measurement precision for automated control while eliminating the reliability issues associated with expensive sensor chains
3Productivity
If full automation is implemented for all excavator parts, then productivity is improved, but device complexity increases due to workflow formalization requirements
Solution Approach 1:
The automated control system divides the excavator's cyclical operations into distinct segments (digging, lifting, carrying, dumping, returning) and applies automated control selectively to each segment. This segmentation allows the system to manage complexity by handling one operation at a time with dedicated control logic, rather than attempting to control all functions simultaneously, thereby improving productivity without overwhelming system complexity
Data Source
AI summary
An earthmoving machine and method for automatically controlling cyclical operations of the earthmoving machine are disclosed. The earthmoving machine includes a plurality of machine elements each controlled by one or more respective actuators. the method comprises: determining a current machine state; calculating control signals for at least one actuator when the current machine state corresponds to a cyclical operation; and transmitting the control signals to the at least one actuator to automatically control the cyclical operation.