Haulage Vehicle Profile Sensing for Precise Material Transfer
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Solution Overview
Problem
The process of transferring harvested material from a transfer vehicle to a haulage vehicle is challenging due to the difficulty in aligning the transfer vehicle with the haulage vehicle, especially when the haulage vehicle's internal geometry is unknown and observation is hindered by dust or tall walls, leading to potential spillage and uneven filling.
Innovation Solution
A control system that utilizes sensors and CAD files to determine the internal geometry of the haulage vehicle, enabling precise positioning and controlled unloading based on the vehicle's volume profile, using sensors like stereo cameras and ultrasound to guide the transfer vehicle into optimal unloading positions and adjust the spout trajectory.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the transfer vehicle manually aligns with the haulage vehicle, then the operator can control the unloading process, but alignment precision is poor and spillage occurs
Solution Approach 1:
The system pre-acquires the internal geometry of the haulage vehicle before the unloading operation. This preliminary action allows the transfer vehicle to calculate and determine the optimal spout trajectory in advance, rather than manually aligning during the unloading process, thereby improving alignment precision without requiring complex real-time adjustment mechanisms
Solution Approach 2:
The system creates a digital copy (3D model) of the haulage vehicle's internal geometry. This virtual model is used to simulate and determine the precise spout trajectory, replacing the need for manual visual alignment and eliminating the imprecision of operator judgment while avoiding complex physical alignment devices
2Loss of information
If the operator visually observes the haulage vehicle interior, then unloading can be controlled, but dust and tall walls obstruct observation
Solution Approach 1:
The system replaces the mechanical/visual observation method with an electronic/digital approach. Instead of relying on the operator's visual observation through the spout, the system uses pre-acquired 3D models and sensor data to digitally represent and analyze the internal geometry, eliminating the harmful effect of dust and obscurants on observation
Solution Approach 2:
The system introduces a digital model as an intermediary between the transfer vehicle and the haulage vehicle. This virtual representation allows the system to 'see' and analyze the internal geometry without physical line-of-sight, bypassing the obstructing dust and tall walls that prevent direct visual observation
3Manufacturing precision
If the spout trajectory is fixed, then the unloading system is simple, but the fill is uneven and spillage occurs
Solution Approach 1:
The system transforms the spout trajectory from a fixed static configuration to a dynamic adjustable path. Based on the pre-acquired internal geometry and calculated optimal trajectory, the spout can dynamically adjust its position and angle during unloading, achieving uniform fill distribution without requiring complex real-time control mechanisms
Solution Approach 2:
The system changes the trajectory parameters (position, angle, height) of the spout based on the calculated optimal path derived from the haulage vehicle's internal geometry. This parameter optimization ensures even material distribution while avoiding spillage, achieving precision without excessive system complexity
4Productivity
If manual alignment and unloading control is used, then equipment cost is low, but transfer efficiency is reduced
Solution Approach 1:
The system performs preliminary acquisition of the haulage vehicle's internal geometry and preliminary calculation of the optimal spout trajectory before the unloading operation begins. This advance preparation enables automated, precise control during the actual transfer process, significantly improving efficiency without requiring complex real-time sensing and control systems
Solution Approach 2:
The system enables the transfer vehicle to autonomously determine its own optimal unloading trajectory based on pre-acquired geometric data. This self-service capability improves transfer efficiency by eliminating manual alignment operations while avoiding the need for complex operator interfaces or control mechanisms
Data Source
AI summary
The internal geometry of a haulage vehicle is identified. A material transfer operation is controlled to transfer material from a material transfer vehicle to the haulage vehicle based on the internal geometry of the haulage vehicle.