Excavator Linkage Calibration with Laser Distance Meter
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Solution Overview
Problem
Existing excavator calibration methods lack precision and efficiency in determining linkage angles and sensor offsets, leading to potential human error and suboptimal machine operation.
Innovation Solution
An excavator calibration framework utilizing a laser distance meter (LDM) and a laser reflector, coupled with a four-bar linkage and control architecture, executes an iterative process to determine precise linkage positions and angles, minimizing human error and optimizing machine operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional calibration methods are used to determine linkage angles, then the process is simpler, but measurement precision and reliability are insufficient
Solution Approach 1:
A laser reflector is introduced as an intermediary object to facilitate precise angle measurement. The reflector is positioned at specific nodes of the four-bar linkage, and the laser distance meter measures distances to these reflectors to calculate linkage angles through coordinate geometry, significantly improving measurement precision
Solution Approach 2:
Traditional mechanical angle measurement devices are replaced with an optical measurement system consisting of a laser distance meter and laser reflector. The system uses laser-based distance measurements and computational geometry to determine linkage angles, achieving higher precision while reducing mechanical complexity
2Productivity
If manual calibration processes are used, then device complexity is lower, but productivity and operation speed are reduced
Solution Approach 1:
The calibration system performs self-calibration through an automated iterative process. The control architecture automatically coordinates the laser distance meter measurements, calculates node positions and linkage angles, and adjusts the four-bar linkage configuration without requiring continuous manual intervention, thereby improving calibration speed
Solution Approach 2:
The control architecture implements feedback control by continuously monitoring laser distance measurements and using the calculated linkage angles to guide further calibration steps. The iterative process refines measurements based on previous results, enabling rapid and accurate calibration
3Measurement precision
If iterative measurement processes are implemented, then measurement precision improves, but loss of time increases
Solution Approach 1:
The system performs preliminary measurements by positioning the laser reflector at each node of the four-bar linkage and measuring distances from a reference point. These preliminary measurements establish initial coordinates that are then used to calculate linkage angles and refine the calibration model
Solution Approach 2:
The calibration process is segmented into discrete measurement steps, with the laser reflector positioned at each node (D, F, G, H) of the four-bar linkage in sequence. Each node is measured and calculated independently, allowing the complex calibration to be broken down into manageable segments that can be executed efficiently
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
The framework enables precise determination of linkage angles and sensor offsets, enhancing the speed, efficiency, and accuracy of excavator operation by reducing human error and improving processing systems.
Implementation Method 1
The LDM is configured to generate one or more measurement signals indicative of a distance and an angle between the LDM and the laser reflector
Implementation Method 2
a laser reflector... generating a measurement signal indicative of a distance and an angle between the LDM and the laser reflector
Data Source
AI summary
An excavator calibration framework comprises an excavator, a laser distance meter (LDM), and a laser reflector. The excavator comprises a linkage assembly (LA), implement, and controller. The LA comprises a boom with point B, stick coupled to point B, and four-bar linkage (4BL) including nodes D, F, G, and H (a dogbone linkage between nodes D and F). The laser reflector is disposed at node F. The nodes F, G, and the point B define an outer triangle BGF that defines with node D three inner triangles DGB, DBF, and DFG. The controller executes an iterative process including determining a node F position based on a LDM/laser reflector measurement signal, determining a node D position based on the node F position, and determining a dogbone angle BDF of DBF based on the node D position. The controller generates an actual dogbone angle based on a series of dogbone angles.