Work Machine Overload Prevention via Adaptive Weight Control
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Solution Overview
Problem
Existing payload monitoring systems in work machines face inaccuracies in weight measurement due to inherent sensor limitations, leading to potential overloading or underloading of haul work machines, with existing calibration methods not addressing these inaccuracies effectively.
Innovation Solution
A method and system that utilize initial and final sensing data from load sensors to determine estimated weights and accuracy metrics, adjusting target weights for the final load to ensure accurate loading within the haul work machine's capacity, incorporating processing to compensate for measurement inaccuracies and prevent overloading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If sensor-based weight measurement is used to monitor payload, then loading control is enabled, but measurement inaccuracies cause overloading or underloading
Solution Approach 1:
The system continuously monitors actual weight measurements during loading and compares them against target weights. When discrepancies are detected, the system provides feedback to adjust subsequent loading operations, ensuring the haul work machine reaches its weight capacity threshold accurately despite initial sensor inaccuracies
Solution Approach 2:
The controller determines target weights for individual loads in advance based on the haul work machine's weight capacity threshold and the number of loads required. This preliminary calculation allows the system to proactively compensate for expected measurement inaccuracies by adjusting target weights before loading occurs
2Productivity
If multiple loads are deposited to fill haul work machine, then weight capacity is utilized, but cumulative measurement errors compound
Solution Approach 1:
After each load is deposited, the system measures the actual weight added and uses this feedback to recalculate the remaining capacity for subsequent loads. This continuous feedback loop prevents cumulative errors by constantly adjusting target weights based on actual measurements rather than relying on inaccurate initial estimates
Solution Approach 2:
The system calculates target weights that may be slightly conservative (partial action) to ensure the total weight does not exceed the capacity threshold. By loading slightly less than the theoretical maximum for each individual load, the system prevents overloading while still achieving full capacity utilization across multiple loads
3Manufacturing precision
If target weight is calculated for final load, then precise loading is achieved, but sensor inaccuracies still affect accuracy
Solution Approach 1:
The controller calculates the target weight for the final load in advance by subtracting the sum of previously loaded weights from the weight capacity threshold. This preliminary determination allows the system to prepare the exact target weight needed, compensating for sensor inaccuracies through systematic calculation rather than relying on potentially erroneous real-time measurements
Solution Approach 2:
The system incorporates a safety margin or cushion in the target weight calculation for the final load to account for expected measurement inaccuracies. By building in this protective buffer beforehand, the system ensures that even if sensor readings are slightly off, the final load will not cause overloading of the haul work machine
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 approach ensures precise loading, preventing overloading or underloading of haul work machines, optimizing material distribution and reducing wear and tear on equipment by maintaining loads within safe capacity thresholds.
Implementation Method 1
sensors may detect changes in pressure (e.g., of the hydraulic cylinders of the linkage)
Implementation Method 2
strain (e.g. of the arm)
Implementation Method 3
pressure (e.g., of the hydraulic cylinders of the linkage)
Data Source
AI summary
A controller may obtain initial sensing data to determine an estimated weight associated with each initial load of one or more initial loads of material carried by an implement. The controller may identify an estimated weigh accuracy metric associated with each initial load and an estimated weight accuracy metric associated with a final load to be carried by the implement. The controller may determine a target weight for the final load based on the estimated weights of the one or more initial loads, the estimated weight accuracy metrics of the one or more initial loads, or the estimated weight accuracy metric associated with the final load. The controller may obtain final sensing data to determine an estimated weight associated with the final load and may cause the implement to perform one or more actions based on the estimated weight of the final load and the target weight.