Work Machine Load Overflow Detection via Controller
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Solution Overview
Problem
Existing payload monitoring systems for work machines, such as hydraulic excavators, face inaccuracies in load measurement due to load overflow issues, which can lead to inefficiencies and errors in loading operations if not promptly addressed.
Innovation Solution
A work machine system that includes a multijoint work implement with an actuator, operation device, and controller capable of calculating load values based on thrust information, posture, and movement state, with a notification system to alert operators of potential load overflows during transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If load measurement is performed during transportation operation without stopping work, then productivity is improved, but measurement precision deteriorates due to load overflow occurrence
Solution Approach 1:
The system performs preliminary detection of load overflow by monitoring the relationship between load value, work implement posture, and movement state during transportation. When load overflow is detected before it significantly impacts measurement accuracy, the system can trigger a remeasurement, thereby maintaining measurement precision while continuing productivity.
Solution Approach 2:
The system continuously monitors load value, posture, and movement state during transportation operation, providing real-time feedback on load overflow conditions. This feedback mechanism allows the operator to be notified and perform remeasurement when necessary, resolving the contradiction between continuous operation and measurement accuracy.
2Ease of operation
If load value is calculated based on actuator thrust information during transportation, then ease of operation is improved, but measurement precision deteriorates due to dynamic conditions
Solution Approach 1:
The system performs preliminary detection of load overflow conditions by monitoring the relationship between calculated load value, work implement posture, and movement state. When overflow is detected, it triggers a remeasurement before the inaccurate measurement is used for loading decisions, thereby maintaining precision while preserving ease of continuous operation.
Solution Approach 2:
The system provides continuous feedback on load overflow detection during transportation operation based on the calculated load value, posture, and movement state. This feedback allows the operator to perform remeasurement when needed, resolving the contradiction between ease of continuous operation and measurement precision.
Data Source
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AI summary
A controller includes a storage device that stores a load overflow reference value defined by a mutual relation between a load value of a work target object, a posture of a work implement, and a movement state of the work implement. The controller calculates the posture of the work implement, and calculates a physical quantity (for example, a swing speed) indicating the movement state of the work implement. The controller estimates whether or not the work implement has caused a load overflow during the transportation of the work target object on the basis of the reference value stored in the storage device, the calculated load value of the work target object, the calculated posture of the work implement, and the calculated physical quantity indicating the movement state of the work implement. When the controller determines that the load overflow has occurred, the controller makes a notification to that effect on a monitor.