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
Engineering 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
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.
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.
2Object-affected harmful factors
If cleanup machines are always dispatched to remove lost loads, then roadways are kept clear, but operational costs increase
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.
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.
3Measurement precision
If comprehensive sensor systems are deployed to detect lost loads, then detection accuracy improves, but system complexity increases
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.
Data Source
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.


