Excavator Payload Monitoring via Velocity Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing payload monitoring systems for excavation machines face challenges in accurately measuring payload during active work cycles due to tool movement, uneven terrain, and environmental factors, often resulting in measurement inaccuracies as they rely on fixed timing and fail to accommodate tool movement.
Innovation Solution
A payload monitoring system that includes sensors for velocity and lift force, a controller to partition the work cycle into segments, and determine a period of stable velocity within the loaded moving segment for accurate payload calculation, allowing dynamic payload determination without interrupting the work cycle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If payload monitoring is performed during active work cycle using fixed timing, then productivity is maintained, but measurement accuracy deteriorates due to tool movement and changing conditions
Solution Approach 1:
The system dynamically determines the optimal measurement timing within the work cycle by detecting when tool velocity is substantially constant, rather than using fixed predetermined timing. This allows the measurement window to adapt to actual operating conditions, resolving the contradiction between maintaining productivity and ensuring measurement accuracy.
Solution Approach 2:
The system continuously monitors tool velocity and uses this feedback to identify the appropriate measurement period. By detecting when velocity stabilizes during the loaded moving segment, the system can select the optimal moment for payload measurement, ensuring accuracy without interrupting the work cycle.
2Device complexity
If measurement window is fixed in time, then system complexity is reduced, but adaptability to changing conditions deteriorates
Solution Approach 1:
The measurement system transitions from static fixed timing to dynamic adaptive timing by detecting velocity stability. This allows the system to automatically adjust to varying work conditions such as different operators, terrain, and environmental factors without increasing overall system complexity.
Solution Approach 2:
The system automatically identifies optimal measurement periods by monitoring its own operational parameters (tool velocity) without requiring external intervention or complex configuration. The work cycle segmentation and velocity analysis are performed autonomously by the control system.
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 approach ensures high accuracy in payload measurement by selecting the most stable velocity period during the work cycle, reducing measurement errors and adapting to changing conditions, thereby improving productivity analysis.
Implementation Method 1
a first sensor configured to generate a first signal indicative of a velocity of the tool
Implementation Method 2
a second sensor configured to generate a second signal indicative of a lift force of the tool
Implementation Method 3
calculate a payload of the tool based on the lift force recorded during the period of time
Data Source
AI summary
A payload monitoring system for an excavation machine is disclosed. The payload monitoring system may have a tool, a first sensor configured to generate a first signal indicative of a velocity of the tool, and a second sensor configured to generate a second signal indicative of a lift force of the tool. The payload monitoring system may also have a controller in communication with the first sensor and the second sensor. The controller may be configured to record the velocity and the lift force of the tool during a work cycle based on the first and second signals, and partition the work cycle into a plurality of segments including a loaded moving segment. The controller may also be configured to determine a period of time within the loaded moving segment during which the velocity of the tool is substantially constant, and calculate a payload of the tool based on the lift force recorded during the period of time.