Haul Route Terrain Mapping for Adaptive Machine Powertrain Control
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Solution Overview
Problem
Existing worksite management systems fail to effectively adapt machine powertrain operations to varying conditions of haul routes, leading to operator discomfort and increased maintenance costs due to rough terrain, as machines are not easily reconfigurable to match actual site conditions.
Innovation Solution
A worksite management system that includes a sensor module with a locating device and Inertial Measurement Units (IMUs) to collect and process data on machine location and terrain conditions, generating alerts and recommending powertrain adjustments, such as reducing speed, to navigate rough areas, and dynamically updating terrain maps for improved route management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If machines are configured conservatively for theoretical conditions, then reliability is improved, but adaptability deteriorates
Solution Approach 1:
The system dynamically adjusts machine powertrain operations based on real-time terrain data from IMUs and locating devices. The worksite management system continuously monitors actual site conditions and modifies machine configuration and operation parameters adaptively, transforming the static conservative configuration into a dynamic system that maintains reliability while adapting to varying terrain conditions.
2Productivity
If machines operate at high speed, then productivity is improved, but operator comfort deteriorates
Solution Approach 1:
The system uses IMUs and locating devices to detect rough terrain conditions in advance before the machine reaches them. By anticipating problematic areas ahead of time, the worksite management system can pre-adjust powertrain output and alert operators, allowing high-speed operation to continue where safe while preparing for speed reduction or route adjustment when rough terrain is detected, thus maintaining productivity while protecting operator comfort.
3Productivity
If machines traverse rough haul routes, then productivity is maintained, but maintenance costs increase
Solution Approach 1:
The system implements continuous feedback through IMUs mounted on the machine that monitor vibration and terrain conditions in real-time. This feedback is transmitted to the worksite management system, which analyzes the data and provides feedback control by adjusting powertrain output, alerting operators to rough areas, and logging maintenance-relevant information. This closed-loop feedback system enables the machine to respond adaptively to rough terrain, maintaining productivity while reducing maintenance costs through proactive management.
4Adaptability or versatility
If terrain conditions are monitored in real-time, then adaptability is improved, but device complexity increases
Solution Approach 1:
The system employs multi-functional IMUs that simultaneously perform multiple functions: detecting terrain roughness, monitoring machine vibration, tracking location, and providing data for both operator alerts and maintenance logging. The worksite management system processes this universal data stream to serve multiple purposes including real-time adaptability, operator comfort protection, and maintenance cost reduction, thereby achieving high adaptability without proportionally increasing device complexity through specialized sensors for each function.
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 system enhances operator comfort and reduces maintenance costs by dynamically adjusting powertrain output based on real-time terrain data, optimizing machine performance and productivity by anticipating and mitigating the impact of rough haul route conditions.
Implementation Method 1
at least one Inertial Measurement Unit (IMU) coupled to the chassis of the machine
Data Source
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AI summary
A worksite management system (300) for a worksite (100) includes a sensor module (302) associated with each of one or more machines (102) working on the worksite (100). The sensor module (302) generates a signal indicative of a location of a corresponding one of a machine (102) from the one or more machines (102). An on-board controller (310) associated with each of the one or more machines (102) receives the signal corresponding to the location of the corresponding one of the machine (102) on the worksite (100), and looks up the location of the corresponding one of the machine (102) in at least one of a pre-generated or learned terrain map (314) of a network of haul routes (110). The on-board controller (310) identifies at least one condition of the haul route (110) at the looked-up location, and then generates an alert for an operator to perform one or more recommended actions with respect to an operating parameter of the corresponding one of the machine (102).