Shovel Controller Automates Diagnostic Data Collection
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Solution Overview
Problem
The complexity of preset operations in shovels with numerous driven parts burdens operators and leads to operational variations due to differences in operator skill, making it challenging to perform consistent and reliable diagnostics.
Innovation Solution
A shovel equipped with state detecting sensors, a controller that executes preset operations based on sensor data, and a mobile information terminal that associates detection values with preset operations, reducing operator burden and variations by automating data collection for analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If preset operations are performed manually by operators according to display instructions, then diagnostic data can be collected, but operator burden increases and operational variations occur due to skill differences
Solution Approach 1:
The shovel system performs self-diagnosis by automatically executing preset operations and collecting sensor data without requiring manual operator intervention. The control unit autonomously manages the diagnostic process, eliminating operator burden and ensuring consistent data collection regardless of operator skill level.
Solution Approach 2:
Preset operations are pre-programmed and stored in the control unit, allowing the system to automatically execute standardized diagnostic sequences. This preliminary preparation ensures that all necessary diagnostic movements are systematically performed without relying on operator memory or skill.
2Ease of operation
If preset operations are automated by controller execution, then operator burden is reduced and operational consistency improves, but system complexity increases
Solution Approach 1:
The control unit serves multiple functions: it controls normal shovel operations, stores preset diagnostic operations, executes automated diagnostics, and manages data collection. This multi-functionality reduces the need for separate dedicated diagnostic hardware, thereby limiting the increase in system complexity.
Solution Approach 2:
The diagnostic function is merged with the existing control system rather than being implemented as a separate system. The control unit integrates preset operation storage, execution control, and sensor data collection into a unified automated diagnostic process, minimizing additional system complexity.
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
This solution reduces operator burden and operational variations, enabling reliable data collection and analysis, thereby improving diagnostic efficiency and accuracy.
Implementation Method 1
an attitude sensor that detects an attitude of the attachment
Implementation Method 2
state detecting sensors that detect operational states of components of the shovel and include an attitude sensor that detects an attitude of the attachment
Data Source
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AI summary
A shovel includes a lower traveling body, an upper rotating body that is rotatably mounted on the lower traveling body, an attachment attached to the upper rotating body, state detecting sensors that detect operational states of components of the shovel and include an attitude sensor that detects an attitude of the attachment, a controller that executes a preset operation based on a detection value detected by the attitude sensor, and a storage that stores detection values detected by the state detecting sensors during execution of the preset operation by the controller in association with the preset operation.