Hydraulic Excavator Loading Cycle Detection for Accurate Truck Payloads
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Solution Overview
Problem
In work-amount monitoring systems, the manual operation of transmitting loaded amounts from work machines to haulage machines or system terminals often leads to errors and inaccuracies due to frequent haulage machine movements, causing operators to forget or misperform the necessary manual operations.
Innovation Solution
A work machine equipped with a work arm, posture sensors, load sensors, a notification device, and a controller that automatically determines the start and end of loading cycles, measures the work target object's weight during the haulage step, and calculates the loaded amount for each haulage machine, ensuring accurate integration and transmission of data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual operation is used to transmit loaded amounts from work machine to haulage machine or system terminal, then the system can be simple in structure, but the accuracy and reliability of loaded amount calculation deteriorates due to operator forgetfulness and mistakes
Solution Approach 1:
The work machine automatically performs the transmission of loaded amounts without requiring manual operator intervention. The controller autonomously calculates loaded amounts by integrating work target object weights measured during haulage steps, and automatically transmits these calculations to haulage machines or system terminals via communication devices, making the system self-sufficient and eliminating human error in data transmission.
Solution Approach 2:
The patent replaces the manual mechanical operation of transmitting data with an automated electronic control system. The controller uses sensors to detect work status, automatically calculates loaded amounts through integration of weight measurements, and transmits data electronically via communication devices, substituting the manual mechanical process with an automated electromechanical system.
2Device complexity
If manual operation is used for transmitting and resetting loaded amounts, then the device complexity remains low, but the productivity and efficiency of work-amount monitoring deteriorates due to frequent manual interventions required
Solution Approach 1:
The controller continuously monitors work status through sensors and continuously integrates work target object weights during haulage steps to calculate loaded amounts in real-time. This continuous automated operation eliminates interruptions for manual data entry and transmission, maintaining uninterrupted monitoring efficiency even as multiple haulage machines arrive and depart frequently.
Solution Approach 2:
The system automatically performs all monitoring, calculation, and transmission functions without requiring operator intervention. The controller self-manages the entire workflow from weight measurement to data transmission, freeing operators to focus on primary work tasks and significantly improving overall work-amount monitoring efficiency.
3Measurement precision
If automatic determination of loading cycles is implemented using posture and load sensors, then the accuracy of loaded amount calculation improves, but the device complexity increases due to additional sensors and control systems
Solution Approach 1:
The posture sensor and load sensor serve multiple functions: they detect work status (excavation, haulage, loading steps), measure physical quantities for calculation, and provide input signals to the controller for automated determination of loading cycles. This multi-functionality justifies the added sensor complexity by enabling precise automatic measurement and control.
Solution Approach 2:
The patent replaces manual observation and estimation methods with automated sensor-based detection. Posture sensors detect the angular positions of work arms to determine operational phases, while load sensors measure forces on the work arm. These electronic measurement systems substitute manual mechanical assessment, providing precise automated determination of loading cycles despite increased device complexity.
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 solution enables accurate calculation and monitoring of loaded amounts for each haulage machine, reducing human error and ensuring precise tracking of production amounts at the work site.
Implementation Method 1
a posture sensor that detects a posture of the work arm including the work device
Implementation Method 2
a load sensor that detects a load acting on the work arm
Data Source
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AI summary
A hydraulic excavator includes a controller that determines the start of loading work for a dump truck and the end of the loading work on the basis of the operation state of the hydraulic excavator at the time of sensing of a work instruction by a horn, integrates a work-target-object weight measured since the start of the loading work until the end of the loading work, and calculates a loaded amount of the dump truck.