Shovel Control Device for Excavation Weight Calculation
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Solution Overview
Problem
Conventional shovels cannot calculate the weight of earth and sand in the bucket when it is in contact with the ground, leading to potential overloading during excavation.
Innovation Solution
A shovel with a control device that sets a target trajectory and excavation volume based on pre-excavation landform information, using sensors and cameras to calculate the weight of excavated material and prevent overloading by adjusting the excavation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If weight calculation is based on hydraulic oil pressure in the boom cylinder, then weight can be calculated when the bucket is lifted, but weight cannot be calculated when the bucket is in contact with the ground
Solution Approach 1:
The system performs preliminary actions by calculating the target excavation volume before the excavation operation starts, using landform information obtained prior to excavation. This allows the system to establish a reference weight calculation method based on volume that can be used from the beginning of the operation, not just after the bucket is lifted.
Solution Approach 2:
The system introduces an intermediary approach by using the relationship between excavation volume and weight as a mediator. When direct weight measurement is unavailable (bucket on ground), the system calculates weight indirectly through volume measurement and density relationships, bridging the gap in measurement capability.
2Productivity
If the bucket takes in earth and sand without weight monitoring, then excavation continues, but overloading occurs because weight cannot be monitored when bucket is on ground
Solution Approach 1:
The system implements feedback control by continuously monitoring the excavation volume and comparing it against the target excavation volume. The control device adjusts the excavation operation in real-time based on this feedback, ensuring that the bucket does not exceed its loading capacity even when direct weight measurement is unavailable.
Solution Approach 2:
The system performs preliminary calculation of the target excavation volume before the excavation operation. This preliminary action establishes a reference value that guides the excavation process, allowing the system to prevent overloading by comparing actual excavation progress against the pre-calculated target.
3Manufacturing precision
If target trajectory is set based on pre-excavation landform information, then excavation precision is improved, but system complexity increases
Solution Approach 1:
The control device performs multiple functions using a unified approach: it calculates both the target excavation volume and the target trajectory based on the same landform information. This multi-functionality reduces the need for separate specialized systems, managing complexity while maintaining high precision.
Solution Approach 2:
The system performs preliminary acquisition and processing of landform information before the excavation operation starts. This preliminary action includes calculating both the target volume and trajectory, which simplifies the real-time control requirements during excavation and manages system complexity by preparing all necessary data in advance.
Data Source
AI summary
A shovel includes a traveling lower body; a revolving upper body rotatably installed on the traveling lower body; an excavation attachment attached to the revolving upper body; and a control device, wherein the control device includes a setting unit to set a target trajectory as a trajectory to be followed by a predetermined part of the excavation attachment, based on information on a landform before excavation is started, and a target excavation volume.