Wheel Loader Stereo Camera Normalcy Check via Equipment Posture

Solution Overview

Problem

Existing work machines face challenges in accurately determining the normalcy of three-dimensional measurement devices used for positioning working equipment, which is crucial for precise automation tasks.

Innovation Solution

A system and method involving a camera mounted on the work machine to estimate the position of working equipment based on its posture and determine the normalcy of the camera by comparing estimated positions with actual positions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a three-dimensional measurement device is used to measure the position of working equipment, then measurement capability is provided, but there is no mechanism to determine whether the device is normal or abnormal

Engineering Contradiction:

Improvedetermination accuracy of device normalcyVSAvoidposition measurement accuracy

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The system performs preliminary abnormality determination at the start of work by comparing the measured position of working equipment with the expected position calculated from machine posture. This preliminary check ensures the measurement device is functioning normally before actual measurement work begins, preventing inaccurate measurements due to device abnormalities.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system establishes a feedback mechanism where the measured position from the three-dimensional measurement device is continuously compared with the expected position derived from machine posture sensors. When discrepancies exceed a threshold, the system generates abnormality notifications and can suspend automated work, ensuring measurement precision is maintained through continuous verification.

Inventive Principle:

Principle #23Feedback

2Productivity

If automated work is implemented using position measurement, then productivity increases, but operational errors occur when the measurement device is abnormal

Engineering Contradiction:

Improvework automation efficiencyVSAvoidoperational accuracy

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system performs preliminary abnormality determination at the start of work by comparing the measured position of working equipment with the expected position calculated from machine posture. This preliminary check ensures the measurement device is functioning normally before actual measurement work begins, preventing inaccurate measurements due to device abnormalities.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system establishes a feedback mechanism where the measured position from the three-dimensional measurement device is continuously compared with the expected position derived from machine posture sensors. When discrepancies exceed a threshold, the system generates abnormality notifications and can suspend automated work, ensuring measurement precision is maintained through continuous verification.

Inventive Principle:

Principle #23Feedback

3Device complexity

If the three-dimensional measurement device is used without verification, then device complexity is reduced, but measurement reliability cannot be ensured

Engineering Contradiction:

Improvemeasurement system simplicityVSAvoidmeasurement device normalcy

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The control device performs multiple functions: it controls the machine posture, calculates expected positions, receives measured positions from the three-dimensional measurement device, compares them for abnormality determination, and manages automated work suspension. This multi-functionality allows reliability verification without adding separate dedicated hardware, maintaining system simplicity while ensuring measurement reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12612767B2Work machine abnormality determination system and work machine abnormality determination method

Publication Date: 2026.04.28 KOMATSU LTD

AI summary

An abnormality determination system applicable to a work machine includes: a stereo camera mounted on a wheel loader having working equipment; a position data calculation unit that estimates a position of the working equipment in a captured image of the stereo camera based on a posture of the working equipment when captured by the stereo camera; and a determination unit that determines whether the stereo camera is normal based on the estimated position of the working equipment.