Load Position Indicator for Excavation Systems
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Solution Overview
Problem
Existing load position display indicators for excavation systems do not provide real-time, comprehensive information on payload distribution and center of gravity, leading to uneven tire loading and excessive wear on mechanical components, as they primarily focus on total payload calculation rather than real-time positioning and orientation during the loading process.
Innovation Solution
A portable, stand-alone computing device with wireless communication interfaces and controllers that receive location and orientation data from both the loader and hauler, calculates a new loading position for the payload based on the actual and target center of gravity, and displays this information on an image representative of the hauler from the loader's perspective, facilitating optimal load placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a payload monitor is used to calculate total payload, then the total payload can be accurately determined, but the vehicle frame and suspension are not protected from overloads due to unsymmetrical distribution
Solution Approach 1:
The system segments the payload measurement function into two independent monitoring components: one for total payload magnitude and another for payload distribution symmetry. This is achieved through multiple sensors (load cells, GPS, orientation sensors) that independently measure different aspects of the payload, allowing the controller to evaluate both total weight and distribution separately to provide comprehensive vehicle protection.
Solution Approach 2:
The controller acts as an intermediary that integrates data from multiple independent sensors (load cells, GPS, orientation sensors) to create a comprehensive view of payload conditions. It processes this intermediary information to generate both total payload calculations and distribution symmetry assessments, enabling protected operation of the vehicle frame and suspension.
2Ease of operation
If real-time load distribution information is provided to the loader operator, then optimal load placement can be achieved, but the system complexity and cost increase
Solution Approach 1:
The controller serves multiple functions simultaneously: it calculates total payload, determines payload distribution symmetry, provides real-time guidance to the operator, and monitors vehicle operational limits. This multi-functionality consolidates what could be separate complex systems into a single integrated unit, reducing overall system complexity while maintaining comprehensive load management capabilities.
Solution Approach 2:
The system provides self-service through automated calculations and real-time feedback. The controller automatically processes sensor data to determine load distribution symmetry and provides guidance information to the operator without requiring manual intervention or complex external systems, simplifying the operational process.
3Loss of information
If the loader operator has a limited field of view during loading operations, then the operator cannot see the hauler position and payload distribution, but adding visual aids increases system complexity
Solution Approach 1:
The system replaces the need for direct visual observation with electronic sensing and computational systems. GPS receivers, orientation sensors, and load cells electronically measure hauler position, orientation, and payload distribution, substituting these mechanical/visual tasks with automated electronic measurement and calculation systems that provide information without adding physical visual aids.
Solution Approach 2:
The controller serves as an intermediary that translates physical conditions (hauler position, payload distribution) into actionable information for the operator. It processes data from multiple sensors and generates guidance information that compensates for the operator's limited field of view, providing comprehensive situational awareness without requiring complex visual display systems.
Data Source
AI summary
A load position indicating system includes a portable, stand-alone computing device for use on the loader. The stand-alone computing device includes a display, a wireless communication interface configured for peer-to-peer direct communication with an electronic control unit (ECU) mounted onboard the hauler, and at least one controller configured to receive a signal indicative of a real time position of an actual center of gravity of a payload carried by the hauler, determine a real time position and orientation of the loader relative to the hauler, determine a target location for the center of gravity of the payload carried by the hauler, calculate a new loading position for a payload to be deposited by the loader onto the hauler based on a difference between the real time position of the actual center of gravity of the payload and the target location of the center of gravity, and display at least one of the new loading position for a payload, the target location for the center of gravity of the payload, and the real time position of the actual center of gravity of the payload on an image representative of the hauler as seen from a perspective of an operator on the loader.