Grapple Payload Transfer Validation Using Discharge Area Boundaries
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Solution Overview
Problem
Conventional payload handling systems in hydraulic excavators with grapples or clamshells fail to accurately determine payload transfer due to the absence of rotational sensors, leading to miscounts when material is re-grabbed outside the intended discharge area.
Innovation Solution
Implement a control system with load and position sensors to detect payload transfer, set discharge boundaries using swing angles and radial distances, and validate discharge events within these boundaries to prevent miscounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional payload handling systems are used without rotational sensors, then device complexity is reduced, but measurement precision deteriorates leading to miscounts of payload transfer
Solution Approach 1:
The patent introduces an intermediary validation mechanism that uses discharge area boundaries as a reference framework. Instead of directly measuring payload transfer with sensors, the system uses the predefined discharge area boundaries to validate whether material discharge events occurred in the correct location, thereby preventing miscounts without requiring complex rotational sensors on each payload unit.
Solution Approach 2:
The patent replaces the mechanical/physical rotational sensor system with a computational validation approach. Instead of using physical sensors to detect payload discharge, the system uses controller-based validation logic that compares discharge event locations against predefined discharge area boundaries, substituting mechanical measurement with computational verification.
2Measurement precision
If rotational sensors are installed to accurately detect payload discharge, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts the essential validation function from complex rotational sensor systems and isolates it into a separate discharge area boundary validation mechanism. By separating the boundary definition and validation functions from the payload detection process, the system achieves accurate measurement without requiring sensors on each payload unit, thereby reducing overall device complexity while maintaining precision.
Solution Approach 2:
The patent creates a virtual copy or representation of the discharge area through predefined boundaries stored in the controller. Instead of using physical sensors to detect actual discharge locations, the system uses a computational model (boundary representation) to validate whether discharge events occurred in the correct area, replacing physical measurement infrastructure with informational copies.
3Productivity
If material discharge is counted without validating discharge location, then productivity is improved by faster processing, but reliability deteriorates due to miscounts
Solution Approach 1:
The patent performs preliminary action by pre-defining discharge area boundaries before payload discharge operations begin. This advance preparation creates a validation framework that can quickly check discharge locations without complex real-time analysis, enabling fast validation that maintains both high productivity and reliable accuracy in payload counting.
Solution Approach 2:
The patent implements a feedback mechanism where the controller continuously monitors payload discharge events and validates them against the predefined discharge area boundaries. This closed-loop feedback system automatically corrects or prevents miscounts by comparing actual discharge locations with expected discharge areas, ensuring reliable productivity measurement without manual intervention.
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
Accurately determines proper payload transfer by preventing double-counting and ensuring material is discharged only within the intended area, enhancing operational efficiency and accuracy.
Implementation Method 1
a load sensor to detect changes in load on the working implement
Implementation Method 2
a position sensor to detect position of the working implement
Data Source
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AI summary
Systems, methods, and apparatuses can accurately determine proper payload transfer from a working implement (24) of a working machine (12). Such systems, methods, and apparatuses can identify occurrence of a payload discharge event for the working implement (24); determine whether a position of the working implement (24) at a time of the identification of the occurrence of the payload discharge event is in a preset working area or a preset discharge area; omit the payload discharge event from registration for a tally of discharge material payload amount under a first case where the position of the working implement (24) is determined to be in the working area; and register the payload discharge event for the tally under a second case where the position of the work implement is determined to be in the discharge area. The tally of the discharge material payload amount may be increased by a load amount associated with the load discharge event.