Excavator Dump Automation via Fixed Rotation Point Control
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Solution Overview
Problem
Modern mobile machinery, such as excavators, face challenges in precisely depositing material during the uncurling motion of the bucket, often resulting in a wide area of deposited material due to uneven release.
Innovation Solution
A computer-implemented method and system that automatically control the arm of an excavator during a material dump operation by setting a fixed rotation point and generating control signals to maintain a constant distance from this point while the bucket is uncurling, ensuring precise material deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the bucket is allowed to uncurl freely during material dump, then the operator has full control over the bucket motion, but the material is deposited over a wide area due to uneven release
Solution Approach 1:
The system continuously monitors the bucket's angular position during uncurling and feeds this information back to the controller. The controller then adjusts the arm's rotation in real-time to compensate for the bucket's motion, ensuring the bucket maintains a consistent angular velocity and deposits material precisely at the target location despite operator control variations.
Solution Approach 2:
The patent replaces manual mechanical control of the arm with an automated control system that uses sensors and processors. The system automatically calculates and executes the arm's rotation path based on the bucket's position, substituting the operator's mechanical control with an intelligent control loop that achieves superior precision.
2Manufacturing precision
If the arm rotates to compensate for bucket uncurling, then material deposition precision is improved, but the control system complexity increases
Solution Approach 1:
The control system is designed to handle multiple functions through a single integrated architecture. The same processor that monitors bucket position also calculates arm rotation commands and coordinates the hydraulic actuators. This multi-functional approach reduces overall system complexity compared to having separate dedicated systems for each function.
Solution Approach 2:
The system pre-calculates the arm's rotation path and speed based on the bucket's expected motion characteristics. By anticipating the bucket's uncurling behavior and preparing the arm's motion in advance, the system reduces real-time computational complexity and achieves smoother, more predictable material deposition.
3Productivity
If the bucket uncurls quickly to improve productivity, then the material dump operation is faster, but the material disperses over a larger area
Solution Approach 1:
The system dynamically adjusts the arm's rotation speed and trajectory in response to the bucket's uncurling rate. When the bucket uncurls quickly, the arm rotates faster to compensate, maintaining the bucket's angular velocity and ensuring material is deposited at the correct location. This dynamic coordination allows quick uncurling without increasing the deposition area.
Solution Approach 2:
The control system maintains continuous coordination between the bucket's uncurling motion and the arm's rotation throughout the entire material dump process. By ensuring the bucket maintains a constant angular velocity from start to finish, the system achieves continuous precise material deposition without gaps or dispersion, regardless of the uncurling speed.
Data Source
AI summary
Described are systems and methods for performing a material dump operation at a construction machine. The machine's control unit receives a first user input to activate a material dump mode. The control unit sets a fixed rotation point in a reference frame that is to be at a constant distance from the bucket pin and/or the leading edge of the bucket. The control unit receives a second user input to cause the bucket to uncurl. While the bucket is uncurling, and in response to receiving the second user input while the material dump mode is activated, the control unit generates one or more control signals causing one or more elements of the machine's arm to vertically rotate so as to maintain the constant distance.