Shape-Changing Machine Collision Boundaries With Dynamic Safety Zones

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Solution Overview

Problem

Existing collision avoidance systems for shape-shifting machinery, such as excavators, are inadequate as they fail to consider rotational and shape changes, and either require limited computational power or high-level computational resources, making them incompatible with small computers and engine control modules.

Innovation Solution

A collision avoidance system that determines first and second safety zones associated with movable portions of the machine, using geometric shapes like rectangles or sectors, and provides notifications or control commands based on the relationship of objects to these zones, utilizing minimal computational power and standard sensors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If complex derivative functions and multiple trajectory calculations are used to consider rotational and shape changes, then collision detection accuracy is improved, but computational power requirements and device complexity increase significantly

Engineering Contradiction:
Improvecollision detection accuracyVSAvoidcomputational complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The machine is divided into multiple segments or points of interest (POIs), each with its own safety zone. Instead of calculating complex trajectories for the entire shape-shifting machine, the system segments the machine into manageable parts (boom, arm, bucket, chassis) and calculates safety zones for each segment independently using simple geometric shapes, thereby reducing computational complexity while maintaining collision detection accuracy.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent uses simple geometric shapes (circles, rectangles, polygons) as safety zones instead of complex mathematical models. These geometric representations are computationally inexpensive to calculate and update, replacing the need for heavy derivative calculations and trajectory simulations while providing sufficient accuracy for collision avoidance.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

2Power

If simple geometric calculations are used to define safety zones, then computational power requirements are reduced, but accuracy in detecting collisions for shape-shifting machines deteriorates

Engineering Contradiction:
Improvecomputational powerVSAvoidcollision detection accuracy
Core Design Contradiction:
PowerVSMeasurement precision

Solution Approach 1:

The safety zones are made dynamic by updating their positions and orientations based on the current configuration of the shape-shifting machine. As the machine changes shape through rotation and movement of its segments, the geometric safety zones corresponding to each segment are recalculated and repositioned in real-time, ensuring accurate collision detection throughout the machine's range of motion without requiring complex predictive trajectory calculations.

Inventive Principle:
Principle #15Dynamics

3Reliability

If multiple trajectories and probability calculations are computed for each point of the machine, then collision probability assessment is improved, but processing time and computational resources increase

Engineering Contradiction:
Improvecollision probability assessmentVSAvoidprocessing time
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The system pre-calculates and stores the geometric properties and safety zone parameters for each segment of the machine in various configurations. During operation, instead of performing complex real-time trajectory and probability calculations, the system retrieves pre-computed safety zone data and performs simple geometric overlap checks with detected objects, significantly reducing processing time while maintaining reliable collision assessment.

Inventive Principle:
Principle #10Preliminary action

Data Source

PatentUS12410586B2Systems and methods for collision avoidance for shape changing machines
Publication Date: 2025.09.09 CATERPILLAR INC
  • US12410586B2 patent drawing
  • US12410586B2 patent drawing
  • US12410586B2 patent drawing

AI summary

A collision avoidance system and method for a mobile machine includes determining a boundary zone and providing a notification and/or control command to prevent a collision with another object. A first safety zone associated with a first and second portion of the mobile machine is determined. A second safety zone associated with the second portion of the mobile machine is determined. A boundary zone is determined as a function of a combination of the first and second safety zone. A notification and/or a control command is provided based on a relationship of an object to the boundary zone.