3D Sensor Volume Estimation for Work Vehicle Containers
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Solution Overview
Problem
Measuring the efficiency of earth-moving operations in work vehicles, such as excavators, is challenging due to the difficulty in accurately estimating the volume of contents in containers without interrupting the process, as traditional methods like weighing require additional steps and may not provide accurate non-contact volume estimation.
Innovation Solution
A system equipped with a 3D sensor, such as a stereo camera, and an angle sensor that captures images of the container's contents and determines the volume by creating a 3D point cloud, allowing for non-contact measurement and accurate volume estimation by comparing the images to a known model, while also considering the container's angle and rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If weighing contents of the bucket is used to measure efficiency, then measurement accuracy is improved, but additional steps are introduced that reduce productivity
Solution Approach 1:
The patent replaces the mechanical weighing system with an optical measurement system using a 3D sensor (stereo camera) to capture images and calculate volume through photogrammetry. This substitution eliminates the need to stop the earth-moving process for weighing, thereby maintaining productivity while achieving accurate volume measurement through computational methods rather than physical intervention.
Solution Approach 2:
The system creates a digital 3D model (copy) of the bucket contents by capturing multiple images from different angles and processing them through stereo vision algorithms. This digital replica allows for accurate volume calculation without physically interacting with the material, enabling continuous operation and maintaining earth-moving efficiency while achieving precise measurement.
2Productivity
If non-contact volume estimation is used, then productivity is maintained, but measurement accuracy deteriorates
Solution Approach 1:
The patent transitions from 2D image capture to 3D volume reconstruction by using a stereo camera system that captures images from multiple viewpoints simultaneously. This dimensional enhancement allows the system to calculate actual three-dimensional volume of bucket contents from optical data, achieving measurement accuracy comparable to weighing methods while maintaining continuous operation and productivity.
Solution Approach 2:
The 3D sensor system serves multiple functions: it captures images for volume calculation, determines bucket orientation through angle detection, and provides continuous monitoring capability. This multi-functionality enables accurate non-contact measurement that maintains both productivity and measurement precision by integrating sensing and calculation into a single unified system.
3Loss of information
If continuous monitoring is implemented, then real-time data availability is improved, but device complexity increases
Solution Approach 1:
The patent combines the 3D sensing capability and angle detection function into an integrated system where the stereo camera and angle sensor work together under unified processing. This merging reduces overall system complexity by coordinating multiple sensors through a single processing framework, enabling continuous real-time monitoring while avoiding the complexity of separate independent monitoring systems.
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 enables accurate and efficient volume estimation of materials in work vehicle containers, improving productivity and reducing costs by providing real-time data to operators and managers, enhancing the accuracy and ease of monitoring material movement.
Implementation Method 1
a 3D sensor, such as a stereo camera, and an angle sensor that captures images of the container's contents
Data Source
AI summary
A volume of contents in a container of a work vehicle can be estimated in various examples. One example involves a system with a 3D sensor on a work vehicle, where the sensor captures images of a material in a container of the work vehicle. A processor device that is in communication with the 3D sensor determines a volume of the material in the container using the images.