Excavator Operation Guidance Using Standard Lever Stroke Feedback
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Solution Overview
Problem
The operational skill level of operators is not considered in existing systems for measuring the operational conditions of hydraulic excavators, leading to inconsistent performance when operators change, affecting the accuracy of movement measurements.
Innovation Solution
An operation guide device for hydraulic excavators that includes potentiometers on operating levers, proportional solenoid valves, posture sensors, and a guide controller to compare operator inputs with standard patterns, providing real-time feedback and guidance to maintain consistent operational conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If operation restraint conditions are controlled based on standard procedures without considering operator skill level, then operational conditions can be standardized, but measurement accuracy deteriorates when operators change due to skill variations
Solution Approach 1:
The system provides real-time feedback to the operator by displaying the difference between actual lever operation and standard operation patterns. The guide controller compares posture sensor data with standard patterns and presents guidance information to help the operator correct deviations, thereby improving measurement accuracy without requiring advanced operator skills.
Solution Approach 2:
Standard operation patterns are pre-stored in the guide controller for various operational conditions. Before measurement begins, the system selects the appropriate standard pattern based on current operational parameters, preparing the reference data in advance to enable accurate comparison during the measurement process.
2Measurement precision
If standard operation patterns are stored and compared with actual operations, then operator skill variations can be compensated, but device complexity increases due to additional sensors and control systems
Solution Approach 1:
The guide controller serves multiple functions: it controls the proportional solenoid valves for hydraulic control, processes posture sensor data, compares actual operations with standard patterns, and provides guidance display. By integrating these functions into a single controller, the system avoids the need for separate dedicated hardware for each function, thereby reducing overall system complexity.
Solution Approach 2:
Posture sensors act as intermediaries between the operating levers and the guide controller, converting mechanical lever positions into electrical signals that can be processed and compared with standard patterns. This intermediary conversion simplifies the control system by providing a standardized interface for measurement and comparison.
3Measurement precision
If real-time comparison and guidance are provided during operation, then measurement accuracy is maintained, but information processing load and response time requirements increase
Solution Approach 1:
Standard operation patterns are pre-calculated and stored in memory for various operational conditions and measurement points. During actual operation, the system only needs to retrieve the relevant standard pattern and compare it with current sensor data, rather than calculating the entire measurement process in real-time, thereby reducing processing time while maintaining accuracy.
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 device reduces the impact of operator skill variations on measurement accuracy by providing immediate feedback and guidance, ensuring consistent operational conditions and improving measurement reliability.
Implementation Method 1
each operating lever is comprised of electric levers and is configured for operating respective operating members, which construct the front working device, and the upperstructure so that operation signals are generated corresponding to input operations by an operator
Implementation Method 2
a plurality of proportional solenoid valves for driving a plurality of actuators for actuating the respective operating members and the upperstructure in correspondence to the operation signals from the potentiometers
Implementation Method 3
a plurality of posture sensors configured for detecting movement quantities of the respective operating members and upperstructure actuated by the proportional solenoid valves, respectively
Data Source
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AI summary
A guide controller that displays an operation guide image for a hydraulic excavator acquires operation signals outputted from operating devices formed of electric operating levers and stores them in a collected data storage section, compares strokes of the operating devices as derived from the operation signals, which are stored in the collected data storage section, with standard strokes corresponding to standard operation procedures out of standard operation pattern data stored in a standard operation pattern storage section, and, if a deviation equal to or greater than a predetermined standard stroke threshold is determined to exist between at least one of the strokes and the corresponding standard stroke, to read the operation guide image from the standard operation pattern storage section and to display it on a display.