Construction Machine Sensor Calibration for Mounting Error Correction
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Solution Overview
Problem
Existing construction machines with machine guidance functions face challenges in accurately assisting operator operations when sensors are not mounted at the correct position or replaced improperly.
Innovation Solution
A work assistance system that includes a sensor unit on a moving part of a construction machine and a portable information terminal device, which acquires and corrects posture information using image processing to account for mounting errors, ensuring accurate operator assistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a sensor is mounted on a moving part of a construction machine, then machine guidance function can be provided, but if the sensor is not arranged at the correct position, measurement accuracy deteriorates
Solution Approach 1:
The system performs preliminary actions by capturing images of the sensor unit at multiple known positions before actual operation, calculates the mounting position in advance, and determines correction values that are stored for subsequent use. This preliminary calibration eliminates the need for precise mounting during operation.
Solution Approach 2:
The patent replaces the mechanical approach of precisely mounting sensors with a computational approach using image processing and coordinate transformations. Instead of relying on mechanical precision, the system uses camera images and mathematical calculations to detect and correct mounting position deviations.
2Ease of manufacture
If sensor mounting position is not precisely controlled, then ease of installation is improved, but operator assistance accuracy deteriorates
Solution Approach 1:
The system enables self-service by allowing the construction machine itself to capture images of the sensor unit using its own imaging device, process the images to detect mounting position, and automatically calculate and apply correction values without requiring external calibration equipment or expert intervention.
Solution Approach 2:
The imaging device serves as an intermediary between the sensor unit and the control system. It captures visual information about the sensor's position, which is then processed to generate correction values that mediate between the actual mounting position and the required accuracy for operator assistance.
3Measurement precision
If image processing is performed to calculate mounting error, then measurement accuracy is improved, but processing time increases
Solution Approach 1:
The system performs image processing and mounting position calculation in advance during a setup phase, before actual operation begins. The correction values are determined preliminarily and stored for rapid retrieval during operation, eliminating time loss during productive work.
Solution Approach 2:
The system performs complete image processing and correction value calculation only once during setup, rather than continuously during operation. This partial action approach (doing the heavy processing once rather than repeatedly) significantly reduces time loss during actual work while maintaining high accuracy.
Data Source
AI summary
The present invention enables proper assistance of an operation by an operator even when a sensor is not disposed in the correct position. In a method for controlling a work assistance system that assists work of an operator by using a machine guidance function, the work assistance system comprises: a sensor unit that is held by a moving part of a construction machine and acquires attitude information by using a sensor; and a portable information terminal device that acquires, by means of data communication with the sensor unit, the attitude information acquired by the sensor unit, and that, on the basis of the attitude information, reports information for assisting an operation by the operator. The method for controlling the work assistance system comprises: an imaging result acquisition step for acquiring an imaging result from the moving part having the sensor unit; an error calculation step for subjecting the imaging result to image processing to calculate a mounting error of the sensor unit with respect to a reference mounting position; and a correction step for using the mounting error to correct the attitude information.