Excavator Work Tool Wear Detection via Weight Analysis

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Solution Overview

Problem

Operators of work machines, such as excavators, face challenges in determining excessive wear or damage of work tools and forgetting to update machine settings when tools are changed, leading to unexpected downtime and inappropriate parameter usage.

Innovation Solution

The implementation of a system that uses sensors to determine the weight of work tools at specific times, comparing it to predetermined weight ranges, and electronically outputs information for further actions, such as inspection or replacement, based on the weight analysis.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual monitoring of work tool condition is used, then the system complexity is low, but the reliability of detecting wear and damage is poor

Engineering Contradiction:

Improvedetection reliabilityVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system enables automatic self-monitoring of work tool condition through sensors that continuously track weight, vibration, and operational parameters. The control unit automatically compares measured values against threshold ranges and generates alerts without operator intervention, allowing the equipment to monitor its own health status.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system implements continuous feedback loops where sensor data from the work tool is fed back to the control unit for real-time analysis. When parameters deviate from acceptable ranges, the system provides immediate feedback through visual or audible alerts, enabling timely maintenance decisions.

Inventive Principle:

Principle #23Feedback

2Measurement precision

If continuous monitoring of work tool weight is implemented, then the measurement precision of tool condition is improved, but the energy consumption increases

Engineering Contradiction:

Improveweight measurement precisionVSAvoidenergy consumption

Core Design Contradiction:

Measurement precisionVSUse of energy by moving object

Solution Approach 1:

The system performs weight measurements and comparisons at periodic intervals rather than continuously. The control unit evaluates work tool weight at defined moments during operation and compares it against stored threshold ranges, reducing energy consumption while maintaining adequate monitoring precision.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

Reference weight ranges and threshold values are pre-programmed into the control unit before operation begins. This preliminary setup allows the system to quickly compare actual measurements against predetermined standards without requiring complex real-time calculations, reducing computational energy demands.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If automatic weight determination is used, then the productivity of maintenance scheduling is improved, but the device complexity increases

Engineering Contradiction:

Improvemaintenance scheduling efficiencyVSAvoidcontrol system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The control unit automatically determines work tool weight and compares it against reference ranges without operator intervention. The system self-manages the entire process from data collection to maintenance alert generation, improving maintenance scheduling productivity while keeping the control logic relatively simple and modular.

Inventive Principle:

Principle #25Self-service

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 timely detection of wear, damage, or tool changes, allowing for planned maintenance, adjusting machine settings, and preventing unexpected downtime due to inappropriate tool usage.

Implementation Method 1

a plurality of inertial measurement unit (IMU) sensors, including a first IMU sensor operatively coupled to the upper swiveling body, a second IMU sensor operatively coupled to the boom, and a third IMU sensor operatively coupled to the stick

Methodology Applied

Scientific EffectInertial measurement: Accelerometer

Implementation Method 2

determine the weight of the work tool under a condition where the excavator is in the state to determine the weight of the work tool, determine that the determined weight of the work tool is outside of a predetermined weight range

Methodology Applied

Scientific EffectWeight determination through sensor analysis:

Data Source

PatentUS20250129579A1System, method, and computer program product for determining work implement wear, damage, or change

Publication Date: 2025.04.24 CATERPILLAR SARL

AI summary

Systems, methods, and computer program products can determine wear, damage, change, or other characteristics of a portion of a front linkage of an excavator. The systems, methods, and computer program products can comprise determining, based on signals from at least one sensor of the excavator, that the excavator is in a predetermined state to weigh at least a portion of the front linkage of the excavator; determining a weight of the portion of the front linkage of the excavator under a condition that the excavator is in the state to weigh the portion of the front linkage of the excavator; determining that the determined weight of the portion of the front linkage is outside of a predetermined weight range; and electronically outputting information regarding a further action to be taken with respect to the portion of the front linkage of the excavator.