Autonomous Lost Load Management for Haul Machines

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Solution Overview

Problem

Existing worksite control systems fail to autonomously and efficiently manage lost loads from heavy equipment, leading to low productivity and potential obstructions, as they often require manual intervention and lack necessary information for effective cleanup.

Innovation Solution

A control system that includes sensors on haul machines to detect lost loads, locating devices to determine their location, and a central controller to calculate the repair value and dispatch cleanup machines based on availability, cost, and threshold quantities, allowing for autonomous decision-making on whether to repair or stockpile the lost material.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual intervention is used to manage lost loads, then operators can respond to lost loads, but productivity decreases and response time increases

Engineering Contradiction:
ImproveproductivityVSAvoidresponse time
Core Design Contradiction:
ProductivityVSLoss of time

Solution Approach 1:

The system enables self-service by automatically detecting lost loads through sensors, determining their location and quantity, and dispatching appropriate cleanup machines without human intervention. The controller autonomously manages the entire process from detection to resolution, allowing the worksite system to service itself and eliminating dependency on manual operator intervention.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The system implements feedback by continuously monitoring the worksite environment with sensors, comparing detected lost loads against threshold quantities, and automatically adjusting machine dispatch decisions based on real-time conditions. The controller receives feedback from sensors and locating devices, processes this information, and generates appropriate dispatch commands to cleanup machines, creating a closed-loop control system that responds dynamically to lost load events.

Inventive Principle:
Principle #23Feedback

2Object-affected harmful factors

If cleanup machines are always dispatched to remove lost loads, then roadways are kept clear, but operational costs increase

Engineering Contradiction:
Improveroadway obstructionVSAvoidoperational cost
Core Design Contradiction:
Object-affected harmful factorsVSLoss of energy

Solution Approach 1:

The system applies parameter changes by introducing threshold quantity criteria and cost-benefit analysis parameters into the dispatch decision-making process. Instead of always dispatching cleanup machines, the controller evaluates whether the quantity of lost load exceeds a threshold and whether the cost of cleanup is justified relative to the value of keeping the roadway clear. This conditional approach optimizes operational costs while maintaining safety.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The system converts the potentially harmful effect of lost loads into a beneficial decision-making opportunity by evaluating whether to dispatch cleanup machines or allow minor obstructions to remain. Rather than automatically eliminating all lost loads, the system sometimes determines that the cost of cleanup exceeds the benefit, and intentionally allows certain small lost loads to remain, thereby converting a safety concern into a cost-optimization opportunity.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

3Measurement precision

If comprehensive sensor systems are deployed to detect lost loads, then detection accuracy improves, but system complexity increases

Engineering Contradiction:
Improvedetection accuracyVSAvoidsystem complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The system applies segmentation by dividing the detection function into multiple specialized sensors positioned at different locations on the haul machine (front, rear, and/or side). Each sensor detects lost loads in its specific zone, and the controller integrates these segmented detection signals to achieve comprehensive coverage and high detection accuracy without requiring a single complex sensor system.

Inventive Principle:
Principle #1Segmentation

Data Source

PatentUS9145661B1Worksite control system for managing lost loads
Publication Date: 2015.09.29 CATERPILLAR INC
  • US9145661B1 patent drawing
  • US9145661B1 patent drawing
  • US9145661B1 patent drawing

AI summary

A control system is disclosed for a worksite. The control system may have a sensor located onboard a haul machine to generate a first signal indicative of a load of material lost, and a locating device to generate a second signal indicative of a location of the haul machine. The control system may also have a controller configured to determine a location at which the load of material was lost based on the first and second signals, and to determine a quantity of the load of material. The controller may also be configured to determine a repair needed at the worksite, to calculate a value of performing the repair, and to selectively dispatch a cleanup machine to perform the repair or to move the load of material to a stockpile location based on the value.