Relative Angle Detection for Construction Machine Superstructure
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Solution Overview
Problem
Construction machines, such as excavators and mining shovels, face challenges in safely operating without damaging their undercarriage components due to the lack of accurate relative positioning between the superstructure and undercarriage, which is exacerbated by the inability to integrate angle sensors in harsh environments, leading to operator reliance for avoiding collisions.
Innovation Solution
A method that involves retrieving a trigger signal at a predetermined relative angle between the superstructure and undercarriage, combining it with an absolute angle uncorrelated to the undercarriage's orientation to calculate the current relative angle, allowing an operator assist system to prevent collisions without the need for additional complex electronic components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an angle sensor is placed in the center of the swivel between the superstructure and the undercarriage to detect relative position, then the measurement precision of relative angle is improved, but the device complexity and manufacturing cost increase due to required design changes in power cable routing and swivel structure
Solution Approach 1:
The patent introduces an intermediary calculation approach: instead of directly measuring relative angle with a sensor in the swivel center, it uses two separate absolute angle sensors (one on undercarriage, one on superstructure) whose readings are mathematically combined to derive the relative angle. This intermediary calculation method avoids the need for complex swivel structure modifications while achieving the same measurement goal.
Solution Approach 2:
The patent segments the single relative angle measurement function into two separate absolute angle measurements. By placing independent absolute angle sensors on the undercarriage and superstructure respectively, and then calculating their difference, the system achieves relative angle measurement without requiring a complex integrated sensor in the swivel center.
2Extent of automation
If electronic components are integrated into the undercarriage to enable Operator Assist system to detect relative position, then the safety and automation level is improved, but the reliability decreases due to harsh operating environment exposing electronic components to damage
Solution Approach 1:
The patent extracts the electronic angle sensing functionality from the harsh undercarriage environment and relocates it to the superstructure where conditions are more favorable. By placing the absolute angle sensor on the superstructure rather than the undercarriage, the system maintains automated relative position detection while protecting electronic components from the harshest environmental exposures.
3Adaptability or versatility
If the superstructure retrieves absolute angle uncorrelated to undercarriage orientation to calculate relative position, then the adaptability to different machine configurations is improved, but the loss of information about direct relative positioning occurs
Solution Approach 1:
The patent implements a feedback calculation mechanism where the Operator Assist system continuously monitors both absolute angle readings (from undercarriage and superstructure sensors) and dynamically calculates the relative angle in real-time. This feedback loop ensures that although no single sensor directly measures relative angle, the system continuously reconstructs this information from the two absolute measurements, preventing any loss of critical positioning data.
Data Source
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Figure 4A
AI summary
A method of operating a construction machine (10), which comprises a superstructure (100) and an undercarriage (200) rotatably coupled thereto. The method comprises retrieving (SI) a trigger signal (T) at a predetermined relative angle (a) between the superstructure (100) and the undercarriage (200) while operating the machine (10); retrieving (S2) an absolute angle (β) of the superstructure (100). The method also comprises calculating (S3) a current relative angle (γ) between the superstructure (100) and the undercarriage (200) on the basis of the trigger signal (T) and the absolute angle (β).