Automatic Loader Dump Control via Image Height Detection
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Solution Overview
Problem
In the construction industry, loaders often face inefficiencies and potential damage during dumping operations due to the bucket or boom being below the height of the receptacle, leading to incomplete dumping and potential damage to both the loader and receptacle.
Innovation Solution
An automatic dump control system for loaders that uses image data from a receptacle sensor and position data to determine the height difference between the bucket and receptacle, adjusting the boom and bucket height to ensure proper alignment and efficient dumping, and controlling the loader's speed to prevent collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the operator manually controls the boom and bucket height during dumping operations, then the system remains simple and easy to operate, but the bucket may be positioned below the receptacle height leading to incomplete dumping and potential damage
Solution Approach 1:
The system performs preliminary height assessment by capturing images of the receptacle and calculating its height before the dumping operation begins. This advance measurement allows the control system to pre-determine the required boom and bucket extension to reach the target height, ensuring the bucket will be properly positioned for complete dumping before material is transferred.
Solution Approach 2:
The system continuously monitors the actual position of the boom and bucket during the dumping operation and compares it with the target position calculated from the receptacle height. Based on this feedback, the control system automatically adjusts hydraulic cylinder extension to maintain precise positioning, ensuring the bucket remains at the optimal height for complete dumping while preventing damage from excessive height.
2Productivity
If the loader moves at high speed towards the receptacle, then productivity increases, but the risk of collision and damage to the loader and receptacle increases
Solution Approach 1:
The system calculates the distance to the receptacle and determines the optimal approach speed before the loader reaches the dumping position. By pre-computing the required braking distance and speed reduction based on the receptacle location and current loader speed, the system ensures safe deceleration is initiated at the appropriate moment, allowing high-speed approach followed by controlled stopping for complete dumping.
Solution Approach 2:
The system continuously monitors the loader's actual speed and position during approach to the receptacle and compares it with the target speed and position. Based on this real-time feedback, the control system automatically adjusts braking force and hydraulic cylinder extension to maintain safe approach speed while ensuring the bucket reaches the correct height before stopping, thus preventing collision while maintaining productivity.
3Reliability
If the boom and bucket are positioned too high above the receptacle, then complete dumping is ensured, but the risk of damaging the receptacle or loader increases
Solution Approach 1:
The system continuously monitors the actual height of the bucket relative to the receptacle during the dumping operation and compares it with the target height calculated from the receptacle height measurement. Based on this real-time feedback, the control system automatically adjusts the hydraulic cylinder extension to maintain the bucket at the precise optimal height - high enough to ensure complete dumping but low enough to prevent damage to the receptacle or loader.
Solution Approach 2:
The system dynamically adjusts the target height parameter based on the measured receptacle height and the specific dumping operation requirements. By calculating the optimal height as a function of receptacle dimensions and loader position, the system ensures the bucket is positioned at the precise height needed for complete dumping while minimizing the risk of damage, rather than using a fixed high position.
Data Source
AI summary
An automatic dump control system and method are disclosed for a loader having a boom and a bucket each positionable by hydraulic cylinders actuated by a hydraulic circuit. The control system includes a source of image data of a receptacle and a source of position data for the boom and the bucket. The control system includes a controller that: determines a height of the receptacle based on the image data; determines a difference between the height of the receptacle and a height of the bucket based on the position data; outputs one or more control signals to the hydraulic circuit to position at least one of the boom and the bucket at a target height above the receptacle; determines that the bucket is positioned over the receptacle; and outputs one or more control signals to the hydraulic circuit to dump a load in the bucket into the receptacle.