Work Machine Controller for Boundary Limit Interference Prevention
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Solution Overview
Problem
Operator fatigue and inefficiencies in work machine operations, particularly in environments requiring precise movement and long hours, lead to inconsistencies and increased machine downtime due to the complexity of controls and reliance on experienced operators.
Innovation Solution
A work machine system comprising a power source, power conversion system, traveling body, moveable structure, user input, positioning sensor, and controller, which uses a position control algorithm to control the movement of the machine and avoid interference with objects, allowing for semi-autonomous operation by generating boundary limits and overriding operator inputs when necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If operator actively monitors work performed at work site, then work quality can be maintained, but operator fatigue increases leading to inconsistencies and machine downtime
Solution Approach 1:
The work machine performs self-monitoring of its own position and movement boundaries through the controller and positioning sensor, eliminating the need for continuous operator vigilance. The system automatically determines whether the moveable structure interferes with objects and provides warnings or overrides, allowing the machine to service itself and maintain consistent work quality without operator fatigue.
2Adaptability or versatility
If multiple controls are provided to move boom arm on excavator, then machine functionality is enhanced, but operator training time increases and efficiency decreases
Solution Approach 1:
The system provides automatic feedback to the operator through visual or audible warnings when the moveable structure approaches or interferes with objects. This feedback mechanism replaces the need for operators to manually monitor multiple controls and understand complex spatial relationships, reducing training requirements while maintaining full machine functionality.
3Reliability
If operator relies on experience to operate work machine, then work quality improves, but personnel challenges increase and efficiency reduces
Solution Approach 1:
The patent replaces the reliance on operator experience and manual monitoring with an automated electronic control system. The controller processes positioning sensor data, determines boundary interference with objects, and automatically warns or overrides operator input, substituting human experience with mechanical/electronic judgment and making the system accessible to operators regardless of experience level.
4Reliability
If processor overrides operator input command, then boundary limit interference with objects is prevented, but operator control authority is reduced
Solution Approach 1:
The system applies preliminary anti-action by providing advance warnings to the operator before actually overriding the control input. The controller first alerts the operator that a boundary limit may be interfered with, and only overrides the operator input command if the interference is confirmed or not corrected, allowing the operator to maintain control authority while preventing object collision.
Data Source
AI summary
A work machine comprising a power conversion system, a ground-engaging mechanism, a traveling body, a moveable structure, a user input, and a controller. The traveling body is coupled to the ground-engaging mechanism which is controllable to move the traveling body relative to the ground surface. The movable structure has an actuator controllable to move the movable structure relative to the traveling body wherein the actuator receives power through the power conversion system. The user input generates a user input signal. The sensor generates a sensory signal. A controller with a processor thereon is operable to execute a position control algorithm to receive a user input signal; receive a sensor signal, determine a position of the movable structure relative to the traveling body; and responsively control the power conversion system to control the ground-engaging mechanism or the actuator to avoid interference of a boundary limit with an object sensed.