Work Machine Heap Height Calculation for Efficient Stockyard Filling
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Solution Overview
Problem
The challenge in efficiently filling a material accumulation site, such as a stockyard, lies in accurately predicting the height of a heap formed by lift-up work to ensure optimal stacking.
Innovation Solution
A system comprising a work machine with a travel body and a work implement, including a bucket, and a controller that determines the height of the material heap based on mechanical dimensions of the machine and implement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the heap height is determined by empirical estimation or trial-and-error stacking, then the operation process is simple, but the filling efficiency and space utilization are insufficient
Solution Approach 1:
The system uses the work machine's own mechanical dimensions (bucket capacity, arm length, counterweight position) to calculate and determine the optimal heap height, eliminating the need for external measurement devices or complex sensing systems. The controller autonomously computes the heap height based on pre-stored mechanical parameters and the relationship formula, making the system self-sufficient and cost-effective while improving filling efficiency.
2Volume of stationary object
If the heap height is increased to improve space utilization, then the storage capacity increases, but the heap becomes unstable and prone to collapse
Solution Approach 1:
The system calculates the optimal heap height by considering the mechanical parameters of the work machine (bucket capacity, arm length, counterweight position) and the relationship between these parameters and heap stability. The controller determines a heap height that maximizes storage capacity while maintaining stability by using the work machine's structural characteristics as the basis for calculation, ensuring the heap does not exceed safe height limits.
3Manufacturing precision
If multiple stacking operations are performed to achieve the desired heap height, then the heap can reach the target height, but the time and number of operations increase
Solution Approach 1:
The system performs preliminary calculation of the optimal heap height before the stacking operation begins. The controller stores the mechanical dimensions of the work machine and uses these parameters to pre-calculate the target heap height based on the established relationship between machine dimensions and heap characteristics. This allows the operator to stack material directly to the calculated height in fewer operations, reducing both time and the number of stacking cycles required.
Data Source
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AI summary
The height of a heap of material formed by a lift-up work is appropriately determined. A work machine main body includes a travel body. A work implement is attached to the work machine main body and includes a bucket. A controller commands operation of the travel body and the work implement. The controller determines a lift-up height (H2) that is a height of material formed by a lift-up work of ascending a slope formed by the material and stacking the material on an upper portion of the slope from a mechanical dimension including a dimension of the work machine main body and a dimension of the work implement.