Loading Machine Weight Estimation Using Traction Force and Bucket Angle
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Solution Overview
Problem
Loading machines struggle to optimize the weight of excavated material loaded onto haul vehicles, which affects the efficiency of the loading process.
Innovation Solution
A control system for loading machines that calculates traction force, bucket angle, and excavated object weight using sensors and a controller to optimize the loading process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the loading machine uses traditional manual or simple methods to estimate excavated object weight, then the device complexity is low, but the measurement precision of excavated object weight is insufficient to optimize loading operations
Solution Approach 1:
The patent replaces traditional mechanical weight measurement methods with a control system that calculates weight based on traction force, bucket angle, and bucket data. This substitution enables precise weight measurement without complex mechanical scales, resolving the contradiction between measurement precision and device complexity.
Solution Approach 2:
The control system acts as an intermediary that processes multiple input parameters (traction force from engine, bucket angle from sensors, bucket data from storage) to calculate the excavated object weight. This intermediary approach enables accurate weight determination through computational synthesis rather than direct mechanical measurement.
2Productivity
If the loading machine continuously monitors and adjusts excavated object weight during operation, then the productivity of loading operations is improved, but the device complexity increases due to continuous sensing and control
Solution Approach 1:
The control system continuously monitors traction force, bucket angle, and calculated weight, using this feedback to determine when the optimal weight is reached and to control the loading process. This feedback mechanism enables continuous optimization of loading operations without requiring overly complex additional hardware.
Solution Approach 2:
The control system performs multiple functions: it monitors engine traction force, reads bucket angle sensors, stores and processes bucket data, calculates excavated object weight, and controls the loading operation. This multi-functionality reduces the need for separate dedicated systems, thereby improving productivity without proportionally increasing device complexity.
3Productivity
If the loading machine adjusts the weight of excavated object to provide optimum weight for haul vehicle, then the productivity of loading operations is optimized, but the ease of operation decreases due to automated weight control requirements
Solution Approach 1:
The control system automatically monitors and adjusts the loading process by calculating weight in real-time and determining when optimal weight is reached. The system serves itself by using the collected data (traction force, bucket angle, bucket data) to autonomously control the loading operation, reducing the operational burden on the operator while maintaining optimized productivity.
Data Source
AI summary
A control system for controlling a loading machine including working equipment having a bucket includes a controller. The controller calculates traction force of the loading machine during excavation work of excavating an object to be excavated with the bucket. The controller acquires a bucket angle representing an angle of the bucket with respect to the horizontal plane during the excavation work. The controller calculates a weight of an excavated object, which is the object to be excavated, held by the bucket based on the traction force, the bucket angle, and bucket data indicating a shape and a dimension of the bucket.