Machine-Mounted Spill Detection Using Camera and Ranging Sensors
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Solution Overview
Problem
Existing spill detection systems for machines, such as those described in U.S. Pat. No. 11,256,932, are limited by the need for a trailing vehicle and are less accurate at longer distances, and their accuracy is affected by vehicle positioning and line of sight, leading to potential misses in spill detection.
Innovation Solution
A machine-mounted system using an inertial measurement unit, a first camera, and a ranging device to detect spills, with a spillage detection system that integrates video and ranging signals to determine spill occurrence and notify other machines on a worksite.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a trailing vehicle with sensors is used to detect spills from a leading vehicle, then spill detection capability is provided, but detection accuracy deteriorates with increasing distance between vehicles
Solution Approach 1:
Instead of having the trailing vehicle detect spills from the leading vehicle, the invention inverts the approach by equipping the leading vehicle with spill detection sensors that detect spills occurring at its own rear, eliminating the distance and line-of-sight problems between vehicles
Solution Approach 2:
The invention introduces an intermediary communication system where the leading vehicle's spill detection sensors transmit spill information to the trailing vehicle or central control system, allowing the trailing vehicle to be informed of spills without needing to directly detect them
2Reliability
If sensors on the trailing vehicle are used to detect spills, then spill detection is achieved, but detection reliability deteriorates when vehicles are at different elevations or lack line of sight
Solution Approach 1:
The detection perspective is inverted from trailing-to-leading to leading-to-self-rear, allowing the leading vehicle to detect spills at its own rear regardless of elevation differences or line-of-sight issues with trailing vehicles
Solution Approach 2:
The leading vehicle's sensor system serves multiple functions: detecting spills at its rear, providing this information to trailing vehicles, and enabling spill detection regardless of relative vehicle positions or elevations
3Reliability
If a camera and ranging detector are used on the trailing vehicle, then spill detection is provided, but the system complexity increases due to multiple sensors and coordination requirements
Solution Approach 1:
The invention extracts the spill detection function from the trailing vehicle and places it on the leading vehicle, simplifying the overall system by eliminating the need for complex inter-vehicle sensor coordination and reducing the number of sensors required on each vehicle
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Accurately detects spills with reduced false positives by combining multiple sensors, enabling effective spill management and site-wide coordination to prevent machine disruptions and economic losses.
Implementation Method 1
an inertial measurement unit configured to detect a movement of the machine in one or more axes of travel
Implementation Method 2
a second spillage detector comprising a ranging device for detecting at least a portion of the material spilled from the bucket by detecting an object at a range
Data Source
AI summary
Spillage of material from one or more machines is managed by a worksite management system. A machine includes a camera and a ranging apparatus (such as a light detection and ranging device) to detect material coming from a machine indicating a spill. In some examples, the machine further has one or more inertial measurement units and/or load cell sensors that are used to confirm whether or not a spill has occurred. The worksite management system receives spill notifications from one or more machines and uses the spill notifications to warn other machines of the spill. The worksite management system can also use the spill notifications to control the movement of the machines to avoid the spill.