Excavator Implement Calibration Using Laser Distance Meter
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Solution Overview
Problem
Existing excavator calibration methods lack precision and efficiency in determining implement dimensions and angle offsets, leading to potential human error and reduced accuracy in operation.
Innovation Solution
An excavator calibration framework utilizing a laser distance meter (LDM), first and second laser reflectors, and a control architecture that calculates implement dimensions and rotation factors based on tilt angle signals and LDM measurements to align the excavating implement with horizontal, enabling precise determination of implement dimensions and profile values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional manual calibration methods are used for excavator implement dimensions, then the process is simpler and requires fewer equipment, but the measurement precision and accuracy are reduced due to human error
Solution Approach 1:
The patent replaces manual mechanical measurement methods with an automated optical measurement system. A laser distance meter (LDM) is used to automatically measure distances between calibration nodes on the excavator implement, eliminating manual measurement and calculation processes. The system uses optical signals instead of mechanical contact measurement, significantly improving precision while reducing human error in data collection and computation.
Solution Approach 2:
The patent introduces calibration nodes as intermediary reference points on the excavator implement. These nodes serve as standardized measurement targets that facilitate precise positioning and measurement. The LDM measures distances to these intermediary nodes, which then serve as the basis for calculating implement dimensions through coordinate transformation algorithms, enabling high-precision indirect measurement.
2Measurement precision
If automated calibration processes are implemented to reduce human error, then measurement accuracy improves, but the complexity of the calibration procedure increases
Solution Approach 1:
The calibration system performs self-calibration through automated data processing. The architecture controller automatically receives LDM measurements, performs coordinate transformations, calculates implement dimensions and angle offsets, and stores the calibration data without requiring manual intervention for calculations. The system serves itself by automatically completing the entire calibration workflow from measurement to result generation.
Solution Approach 2:
The system implements feedback through iterative coordinate transformation and validation. The architecture controller continuously processes LDM measurements, transforms coordinates between different reference frames, and refines implement dimension calculations until convergence is achieved. This feedback loop ensures high accuracy while automating the complex mathematical transformations required for precise calibration.
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
This method enhances the accuracy and efficiency of excavator operations by minimizing human error and providing precise implement dimensions, allowing for more precise control and alignment of the excavating implement.
Implementation Method 1
The LDM is configured to generate a first LDM distance signal DLDM1 indicative of a distance between the LDM and the first laser reflector and a first LDM angle of inclination signal θINC1 indicative of an angle between the LDM and the first laser reflector
Implementation Method 2
a first laser reflector is positioned at a first calibration node on the excavating implement... a second laser reflector is positioned at a second calibration node on the excavating implement
Data Source
AI summary
A framework comprises a laser distance meter (LDM), first and second laser reflectors at respective nodes, and an excavator including a chassis, a linkage assembly (LA) including a boom and stick, an implement including the nodes and tilting about axis TA, an implement sensor generating signal θtilt, and architecture. The LDM generates LDM distance signals DLDM and LDM angle of inclination signals θINC between the LDM and the laser reflectors. The architecture comprises LA actuators and a controller programmed to determine the TA relative to horizontal based on θtilt and execute an iterative process to curl the excavating implement and create bucket angles, align the LDM and the first node to determine a set of rotated IDV, align the LDM and the second node to determine a set of rotated IPV, and determine implement dimensions between the nodes based on the set of rotated IDV and IPV.