Task-Dependent Machine Control System for Power Optimization
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Solution Overview
Problem
Existing machine control systems for heavy equipment, such as excavators, are inefficient as they do not accurately classify the tasks being performed by the work implement, leading to suboptimal fuel consumption, noise levels, and productivity, as they only detect actuator operation rather than task-specific requirements.
Innovation Solution
A machine control system that includes a power source, operator input devices, and a controller capable of classifying the current task and selecting an output map to adjust power source operation based on the task classification and desired mode of operation, allowing for precise control of power output to match the task's requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the primary mover output is set to a high level to ensure sufficient power for all conditions, then the machine has immediately available power for any task, but fuel consumption, exhaust emissions, and engine noise increase excessively
Solution Approach 1:
The system dynamically adjusts the primary mover output level based on the detected work implement task. Instead of maintaining a fixed high output, the controller modifies the output level (e.g., operating point, governor setting) according to the specific task requirements such as digging, lifting, or traveling, thereby optimizing the balance between available power and fuel consumption.
Solution Approach 2:
The system changes the operating parameters of the primary mover (such as speed, torque, or governor setting) based on task classification. By detecting the current task through sensors and comparing it with stored task profiles, the system adjusts the primary mover parameters to match the actual power requirements, reducing excess fuel consumption while maintaining sufficient power for the specific task.
2Power
If the primary mover output is set to a high level to ensure sufficient power for all conditions, then the machine has immediately available power for any task, but engine noise increases excessively
Solution Approach 1:
The system dynamically adjusts the primary mover output level based on the detected work implement task. Instead of maintaining a fixed high output, the controller modifies the output level (e.g., operating point, governor setting) according to the specific task requirements such as digging, lifting, or traveling, thereby optimizing the balance between available power and fuel consumption.
Solution Approach 2:
The system changes the operating parameters of the primary mover (such as speed, torque, or governor setting) based on task classification. By detecting the current task through sensors and comparing it with stored task profiles, the system adjusts the primary mover parameters to match the actual power requirements, reducing excess fuel consumption while maintaining sufficient power for the specific task.
3Device complexity
If the control system only detects whether actuators are in operation (on or off) rather than the specific task being performed, then the control system is simpler, but the prime mover maximum revolution number and pump maximum displacement volume may be set too high or too low for the actual task
Solution Approach 1:
The system uses feedback from multiple sensors (work implement position sensors, speed sensors, pressure sensors) to continuously monitor the actual task being performed. The controller compares the current sensor data with stored task profiles and adjusts the prime mover and pump settings accordingly, enabling precise task detection and optimal power delivery.
Solution Approach 2:
The system introduces an intermediary task classification mechanism that translates complex sensor data into recognized task profiles. This intermediary layer (task detection module) processes sensor signals and identifies the current task type, which then guides the controller to select appropriate operating parameters, bridging the gap between simple actuator detection and precise task-aware control.
4Device complexity
If the control system only sets the prime mover maximum revolution number rather than controlling both speed and torque, then the control system is simpler, but the ground speed and thus productivity may be limited for certain tasks
Solution Approach 1:
The system changes the operating parameters of the primary mover (such as speed, torque, or governor setting) based on task classification. By detecting the current task through sensors and comparing it with stored task profiles, the system adjusts the primary mover parameters to match the actual power requirements, reducing excess fuel consumption while maintaining sufficient power for the specific task.
Data Source
AI summary
A control system for a machine is disclosed. The control system may have a power source, an operator input device configured to generate a first signal indicative of a desired mode of power source operation, and a work implement driven by the power source. The control system may also have a controller in communication with the power source and the operator input device. The controller may be configured to classify a currently performed work implement task and select an output map based on the classification of the currently performed work implement task and the first signal. The controller may further be configured to control the power source operation using the output map.