Machine Control System for Collision Avoidance

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Solution Overview

Problem

Large machines such as rope shovels and excavators face challenges in efficiently moving material without displacing it into undesired areas, leading to reduced performance and increased collision risks due to limited visibility and size constraints, necessitating additional machines to manage displaced material while avoiding collisions.

Innovation Solution

A control system that includes a first machine with a material engaging work implement and a pose sensor, and a second machine with a ground engaging drive mechanism, where a controller determines operation zones for both machines based on kinematic models and poses to generate command signals for the first machine to move within its operation zone, avoiding collisions and optimizing material movement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If additional smaller machines are operated in close proximity to larger machines to move undesired material, then the efficiency of the larger material moving machines is improved, but the risk of collisions between machines increases

Engineering Contradiction:

Improveefficiency of material moving machinesVSAvoidcollision risk between machines

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

A control system acts as an intermediary between multiple machines, coordinating their operations through centralized control. The system receives input from operators and automatically controls machine movements, maintaining safe distances and preventing collisions while enabling efficient material removal operations

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The control system continuously monitors machine positions, operational status, and environmental conditions, using this feedback to dynamically adjust machine movements and maintain safe operating parameters, thereby preventing collisions while optimizing productivity

Inventive Principle:

Principle #23Feedback

2Productivity

If the size of machines is increased to move large amounts of material, then the material moving capacity is improved, but the ability to quickly stop to avoid collisions is reduced

Engineering Contradiction:

Improvematerial moving capacityVSAvoidbraking capability

Core Design Contradiction:

ProductivityVSSpeed

Solution Approach 1:

The control system performs preliminary actions by pre-planning machine movement paths and predicting potential collision scenarios before they occur. It proactively adjusts trajectories and speeds to prevent collision situations, rather than relying on reactive braking

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system replaces mechanical braking systems with electronic control mechanisms that can rapidly adjust machine movement through coordinated control of drive systems, achieving faster and more precise stopping capability than mechanical brakes alone

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If the size of machines is increased to handle large amounts of material, then the material handling capability is improved, but the visibility from within the machines is limited

Engineering Contradiction:

Improvematerial handling capabilityVSAvoidvisibility from machine

Core Design Contradiction:

ProductivityVSIllumination intensity

Solution Approach 1:

The control system creates virtual copies and representations of the physical environment using sensor data, cameras, and LIDAR. These digital models provide operators with comprehensive situational awareness and machine status information that compensates for limited physical visibility from within large machine cabs

Inventive Principle:

Principle #26Copying

4Reliability

If avoidance zones are generated around machines to reduce collision likelihood, then the collision risk is reduced, but the operational flexibility of machines is constrained

Engineering Contradiction:

Improvecollision avoidanceVSAvoidoperational flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The avoidance zones are made dynamic rather than static, continuously adjusting their size, shape, and position based on real-time machine operations, environmental conditions, and predicted movement paths. This allows machines to operate flexibly within safe parameters while maintaining collision avoidance

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system dynamically changes operational parameters such as machine speed, position, and trajectory based on real-time conditions and avoidance zone requirements, enabling flexible operation within safety constraints through continuous parameter optimization

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS10480157B2Control system for a machine

Publication Date: 2019.11.19 CATERPILLAR INC

AI summary

A system for controlling operation of a first material engaging work implement includes a first machine, a second machine, and a controller. The controller is configured to store a kinematic model and characteristics of the implement system, determine a second machine operation zone, with the second machine operation zone being defined by a material movement plan of the second machine, and determine a current pose of the first machine. The controller is further configured to determine a first machine operation zone based upon the pose of the first machine, the kinematic model and characteristics of the implement system, and the second machine operation zone, with the first machine operation zone being spaced from the second machine operation zone, and generate a plurality of command signals to move the first material engaging work implement within the first machine operation zone between a first position and a second position.