Working Machine Control System for Payload Weight Accuracy
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Solution Overview
Problem
Existing control systems for working machines fail to efficiently load a load receiving vessel to its desired payload without risking overloading or underloading, which can lead to structural issues, increased wear, and higher operational costs.
Innovation Solution
A control system that determines if the next bucket load is a final load by calculating the difference between the desired payload and the accumulated weight of previously loaded buckets, and provides an indication to the operator whether the final load should be a fully loaded or half-loaded bucket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the operator manually controls the loading process without assistance, then the operator has full control over the loading operation, but the risk of overloading or underloading the load receiving vessel increases
Solution Approach 1:
The control system continuously monitors the accumulated weight of material in the load receiving vessel and provides real-time feedback to the operator through visual or audible signals. The system calculates the difference between the desired payload and current weight, and signals when the next bucket should be fully loaded or partially loaded to achieve the target payload accurately.
Solution Approach 2:
The system automatically performs calculations of weight differences and determines the optimal loading strategy without requiring manual computation by the operator. The control system serves itself by autonomously processing weight data and generating loading instructions, reducing the cognitive burden on the operator while maintaining reliability.
2Reliability
If the operator performs additional steps to avoid overloading (such as controlled dumping of excess material), then the risk of overloading is reduced, but the time needed to fill the load receiving vessel increases
Solution Approach 1:
The control system calculates in advance whether the next bucket load should be full or partial based on the current accumulated weight and desired payload. By determining the optimal loading strategy before the loading action occurs, the system prevents the need for corrective actions like controlled dumping of excess material, thereby maintaining high loading speed while preventing overloading.
Solution Approach 2:
The system strategically applies partial bucket loads when appropriate, rather than always loading to full capacity. This allows precise control over the final payload without requiring the bucket to be fully loaded in every instance, eliminating the need to dump excess material and maintaining productivity.
3Reliability
If the load receiving vessel is underloaded to avoid overloading risks, then the safety margin is increased, but the productivity decreases due to more trips required
Solution Approach 1:
The control system provides continuous feedback on the accumulated weight and calculates the precise difference to the desired payload. This allows the operator to confidently load to or near the maximum capacity without fear of overloading, as the system will indicate when a partial load is appropriate, thereby maximizing each trip's payload while maintaining safety.
Solution Approach 2:
The system dynamically adjusts the loading parameter (full bucket vs. partial bucket) based on real-time weight measurements and the desired payload target. This flexibility allows the system to optimize each loading operation to be as close to maximum capacity as possible without exceeding it, maximizing productivity while maintaining safety margins.
Data Source
Figure 1A~1C
Figure 1D
Figure 2~3
AI summary
The present disclosure relates to a control system 150 for assisting an operator of a working machine, the working machine comprising a bucket arranged to receive a load to be unloaded to a load receiving vessel. T he control system comprises processing circuitry 201 arranged in communication with an operator interface 202. The processing circuitry is adapted to estimate a difference between a desired payload for the load receiving vessel and an accumulated weight of buckets of loads already unloaded to the load receiving vessel using the bucket; determine if the difference corresponds to an estimated weight for a fully loaded bucket or to an estimated weight for a half-loaded bucket; and instruct, using the operator interface and based on the determination, an operator of the working machine to unload a fully loaded bucket or a half-loaded bucket to the load receiving vessel. The present disclosure also relates to a method for operating the control system and to a computer program product.