U.S. patent application number 13/896099 was filed with the patent office on 2014-11-20 for load release height control system for excavators.
This patent application is currently assigned to Caterpillar Global Mining LLC. The applicant listed for this patent is Caterpillar Global Mining LLC. Invention is credited to James Ryan.
Application Number | 20140338235 13/896099 |
Document ID | / |
Family ID | 51894640 |
Filed Date | 2014-11-20 |
United States Patent
Application |
20140338235 |
Kind Code |
A1 |
Ryan; James |
November 20, 2014 |
LOAD RELEASE HEIGHT CONTROL SYSTEM FOR EXCAVATORS
Abstract
An excavator includes a dipper assembly configured to receive a
dipper load, the dipper assembly having an actuated position for
emptying the dipper load, a sensor assembly configured to monitor
one or more operating conditions of the excavator, and a control
module. The control module is configured to receive signals from
the sensor assembly, determine a height of the dipper assembly
relative to a surface, and inhibit movement of the dipper assembly
to the actuated position.
Inventors: |
Ryan; James; (South
Milwaukee, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Caterpillar Global Mining LLC |
Oak Creek |
WI |
US |
|
|
Assignee: |
Caterpillar Global Mining
LLC
Oak Creek
WI
|
Family ID: |
51894640 |
Appl. No.: |
13/896099 |
Filed: |
May 16, 2013 |
Current U.S.
Class: |
37/443 ;
701/50 |
Current CPC
Class: |
E02F 3/4075 20130101;
E02F 3/308 20130101; E02F 3/435 20130101; E02F 9/265 20130101 |
Class at
Publication: |
37/443 ;
701/50 |
International
Class: |
E02F 3/43 20060101
E02F003/43 |
Claims
1. An excavator, comprising: a dipper assembly configured to
receive a dipper load, the dipper assembly having an actuated
position for emptying the dipper load; a sensor assembly configured
to monitor one or more operating conditions of the excavator; and a
control module configured to: receive signals from the sensor
assembly; determine a height of the dipper assembly relative to a
surface; and inhibit movement of the dipper assembly to the
actuated position.
2. The excavator of claim 1, wherein the control module is
programmed to prevent movement of the dipper assembly to the
actuated position when the height of the dipper assembly relative
to the surface is greater than a dipper height limit.
3. The excavator of claim 2, wherein the one or more operating
conditions of the excavator comprise the height of the dipper
assembly relative to the surface.
4. The excavator of claim 3, wherein the control module is
programmed to calculate the dipper height limit at least in part
from the signals received from the sensor assembly.
5. The excavator of claim 2, wherein the sensor assembly is
configured to monitor a weight of the dipper load, and the control
module is programmed to calculate the dipper height limit at least
partly based on the weight of the dipper load.
6. The excavator of claim 1, wherein the control module is
programmed to calculate the height of the dipper assembly relative
to the surface based at least in part on the signals received from
the sensor assembly.
7. The excavator of claim 2, wherein the control module is
configured to provide a warning to an operator of the excavator
when the height of the dipper assembly relative to the surface is
greater than the dipper height limit.
8. The excavator of claim 2, wherein the control module is
configured to control the dipper assembly, the control module being
programmed to automatically lower the height of the dipper assembly
to a position below the dipper height limit before allowing the
dipper assembly to move to the actuated position.
9. The excavator of claim 1, wherein the sensor assembly comprises
a laser sensor configured to measure a distance relative to the
dipper assembly.
10. The excavator of claim 1, wherein the sensor assembly comprises
a laser scanner configured to build a three-dimensional map of an
area surrounding the dipper assembly.
11. The excavator of claim 1, wherein the sensor assembly comprises
an infrared sensor configured to measure a distance relative to the
dipper assembly.
12. A mining shovel, comprising: a dipper configured to receive a
dipper load, the dipper having an open dipper bottom; a dipper door
coupled to the dipper, the dipper door having a first position for
covering the open dipper bottom and a second position for emptying
the dipper load; a sensor assembly configured to monitor a height
of the dipper relative to a surface; and a control module
configured to receive signals from the sensor assembly, and to
control the movement of the dipper door between the first and
second positions.
13. The mining shovel of claim 12, wherein the control module is
programmed to prevent movement of the dipper door from the first
position to the second position when the height of the dipper
relative to the surface is greater than a dipper height limit.
14. The mining shovel of claim 13, wherein the sensor assembly is
configured to monitor one or more operating conditions of the
mining shovel.
15. The mining shovel of claim 14, wherein the control module is
programmed to calculate the dipper height limit at least in part
from the signals received from the sensor assembly.
16. The mining shovel of claim 13, wherein the control module is
configured to slow movement of the dipper door from the first
position to the second position when the height of the dipper
relative to the surface is greater than the dipper height
limit.
17. The mining shovel of claim 13, wherein the control module is
configured to control the dipper, the control module being
programmed to automatically lower the height of the dipper to a
position below the dipper height limit before allowing the dipper
door to move to the second position.
18. A control system for a dipper assembly having an actuated
position for emptying a dipper load, the control system comprising:
a sensor assembly configured to: monitor a height of the dipper
assembly relative to a surface; and monitor a weight of the dipper
load; a control module configured to: receive signals from the
sensor assembly; calculate a dipper height limit based on the
signals; and inhibit movement of the dipper assembly to the
actuated position when the dipper assembly is above the dipper
height limit.
19. The control system of claim 18, wherein the control module is
configured to create a response when the height of the dipper
assembly relative to the surface is greater than the dipper height
limit.
20. The control system of claim 18, wherein the control module is
configured to control the dipper assembly, the control module being
programmed to automatically lower the height of the dipper assembly
to a position below the dipper height limit before allowing the
dipper assembly to move to the actuated position.
Description
TECHNICAL FIELD
[0001] This disclosure relates to excavators having a dipper or
bucket, and particularly to a control system for controlling the
movement of the dipper or bucket. The disclosure relates more
particularly to a control system for controlling a height above a
deposit point at which the excavator releases its load from the
dipper.
BACKGROUND
[0002] This section is intended to provide a background or context
to the invention recited in the claims. The description herein may
include concepts that could be pursued, but are not necessarily
ones that have been previously conceived or pursued. Therefore,
unless otherwise indicated herein, what is described in this
section is not prior art to the description and claims in this
application and is not admitted to be prior art by inclusion in
this section.
[0003] Excavators, such as mining shovels, often include a shovel
dipper or bucket for scooping earth and other materials. The shovel
dipper may be formed with teeth at its leading edge and a dipper
door that closes the rear of the dipper to hold the materials that
are loaded into the dipper by the action of the mining shovel. The
dipper door is typically held closed while the dipper is being
loaded and while the load in the dipper is swung to a deposit point
(e.g., haul truck, dumpster, etc.). At that point, the dipper door
is opened to allow the contents of the dipper to empty.
[0004] Typically, a shovel operator controls the movement of the
dipper, "tripping" (i.e., releasing) the dipper door once the
dipper is above the deposit point, allowing the contents of the
dipper (i.e., the "dipper load") to empty into or onto the deposit
point. In some instances, the impact from the falling dipper load
may cause damage to the deposit point. For example, if the dipper
load is emptied from an excessive height to a load transport
vehicle ("haul truck"), the dipper load may deliver an excessive
force upon impact, causing damage to one or more components of the
haul truck, such as the truck bed, vehicle suspension, etc. The
height at which the dipper load may be safely emptied depends on a
number of factors, including the type of excavator, the type of
deposit point, the weight of the dipper load, and the type of
material comprising the dipper load. Most excavators are manually
controlled by an operator who must determine an appropriate release
height for each dipper load, which can lead to damage to the
deposit point, excavator, or other surrounding equipment due to
operator error or misjudgment.
[0005] Some excavators may include swing automation intended to
restrict the motion of the dipper or bucket. An example of such
swing automation can be found in U.S. Patent Publication No.
2012/0263566, published Oct. 18, 2012, for "Swing Automation for
Rope Shovel," which discloses a controller which monitors the hoist
and crowd position of the dipper, and prevents motion of the dipper
"past a boundary limit of the ideal path." However, the disclosed
controller prevents movement of the dipper outside of an ideal
swing path, which may restrict the excavator from efficiently
performing certain necessary or useful operations. The disclosed
controller also includes only a single ideal path for the dipper,
rather than accounting for the weight of the dipper load, the
height of the deposit point, or any other factors or conditions
related to the operation of the excavator, or location of the haul
truck, etc.
SUMMARY
[0006] An embodiment of the present disclosure relates to an
excavator. The excavator includes a dipper assembly configured to
receive a dipper load, the dipper assembly having an actuated
position for emptying the dipper load, a sensor assembly configured
to monitor one or more operating conditions of the excavator, and a
control module. The control module is configured to receive signals
from the sensor assembly, determine a height of the dipper assembly
relative to a surface, and inhibit movement of the dipper assembly
to the actuated position.
[0007] Another embodiment of the present disclosure relates to a
mining shovel. The mining shovel includes a dipper configured to
receive a dipper load, the dipper having an open dipper bottom, a
dipper door coupled to the dipper, the dipper door having a first
position for covering the open dipper bottom and a second position
for emptying the dipper load, a sensor assembly configured to
monitor a height of the dipper relative to a surface, and a control
module configured to receive signals from the sensor assembly, and
to control the movement of the dipper door between the first and
second positions.
[0008] Another embodiment of the present disclosure relates to a
control system for a dipper assembly having an actuated position
for emptying a dipper load. The control system includes a sensor
assembly configured to monitor a height of the dipper assembly
relative to a surface and monitor a weight of the dipper load, and
a control module configured to receive signals from the sensor
assembly, calculate a dipper height limit based on the signals, and
inhibit movement of the dipper assembly to the actuated position
when the dipper assembly is above the dipper height limit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The disclosure will become more fully understood from the
following detailed description, taken in conjunction with the
accompanying figures, wherein like reference numerals refer to like
elements, in which:
[0010] FIG. 1 is a side view of a mining shovel of the present
disclosure, according to an exemplary embodiment.
[0011] FIG. 2 is a perspective view of a dipper assembly for the
mining shovel of FIG. 1, according to an exemplary embodiment.
[0012] FIG. 3 is a side view of a dipper assembly for the mining
shovel positioned above a haul truck, according to an exemplary
embodiment.
[0013] FIG. 4 is a schematic representation of the load release
height control system of the present disclosure, according to an
exemplary embodiment.
[0014] FIG. 5 is a flow chart representation of the load release
height control system of the present disclosure, according to an
exemplary embodiment.
DETAILED DESCRIPTION
[0015] Before turning to the figures, which illustrate the
exemplary embodiments in detail, it should be understood that the
present application is not limited to the details or methodology
set forth in the description or illustrated in the figures. It
should also be understood that the terminology is for the purpose
of description only and should not be regarded as limiting.
[0016] Referring to FIGS. 1 and 2, a mining shovel 10 having a
dipper 12 is shown, according to an exemplary embodiment. In this
embodiment, the mining shovel 10 includes a dipper arm 20 coupled
to a dipper 12 and supported by a boom assembly 22. The dipper 12
includes teeth forming a leading edge 14 for scooping earth and
other material (e.g., rock, sand, etc.) and has an open dipper
bottom 18 covered by a dipper door 16. The dipper 12 together with
the dipper door 16 may form a dipper assembly. In other
embodiments, the dipper assembly may include other parts or
components as is suitable for the particular application of the
mining shovel 10 and/or the load release height control system of
the present disclosure. Material is loaded into the dipper 12 by
the action of the mining shovel 10, and the dipper door 16 is
configured to cover the open dipper bottom 18 to prevent the
material (i.e., the dipper load) from emptying prematurely. In an
exemplary embodiment, the dipper door 16 is movable between a
closed position (shown in FIGS. 1 and 2) for covering the open
dipper bottom 18, and an open position (i.e., actuated position)
for emptying the contents of the dipper 12. The dipper door 16 is
held in the closed position while the dipper 12 is being loaded and
while the dipper load is swung to a deposit point such as haul
truck 28 (shown in FIG. 3). The dipper door 16 is then released to
the open position, emptying the dipper load at a height above the
deposit point. In the illustrated embodiment of FIGS. 1-3, the
mining shovel 10 includes trip ropes 32 coupled to the dipper door
16 and configured to release the dipper door 16, allowing the
dipper door 16 to swing or move to the open position. In this
embodiment, the trip ropes 32 may be controllable by an operator of
the mining shovel 10, such that the operator is able to "trip"
(i.e., release) the dipper door 16 (i.e., by manipulating a control
panel or otherwise), allowing the dipper door 16 to swing or move
to the open position and emptying the contents of the dipper
12.
[0017] Although the disclosure is shown and described by way of
example with reference to mining shovel 10, the disclosure is also
applicable for use with any digging machine having a dipper (e.g.,
dipper 12, etc.) or bucket for scooping and emptying loads of
material, such as excavators, wheel loaders, etc., all of which are
intended to be within the scope of this disclosure.
[0018] Referring now to FIG. 3, the dipper assembly is shown
positioned above a deposit point shown as haul truck 28, according
to an exemplary embodiment. In this embodiment, the haul truck 28
includes a truck bed 30 for receiving a dipper load. The mining
shovel 10 is configured to scoop material into the dipper 12 in
order to fill the dipper 12 with a dipper load, swing the dipper 12
to a height above the truck bed 30, and then rotate the dipper 12
such that the dipper bottom 18 is oriented to face the truck bed 30
(i.e., such that the closed dipper door 16 is on the bottom of the
dipper 12, according to FIG. 3). Once the dipper 12 is properly
oriented above the surface of the truck bed 30, the dipper door 16
may be released to reveal the open dipper bottom 18 and empty the
dipper load into the truck bed 30.
[0019] Referring to FIG. 4, in an exemplary embodiment the mining
shovel 10 includes a control system (i.e., load release height
control system) that, among other control features, is intended to
prevent or otherwise inhibit the mining shovel 10 from emptying the
dipper load under conditions in which the impact of the dipper load
may apply an excessive load force to the haul truck 28 (or another
deposit point). For instance, an excessive load force may be
applied to a deposit point such as haul truck 28 when the dipper
contents are released from above a certain height relative to the
deposit point or relative to a surface of the deposit point
(hereinafter referred to as "the dipper height limit"). The dipper
height limit may be calculated or determined based on a number of
factors, including the weight of the dipper load, the type of
material comprising the dipper load, the specific characteristics
of the deposit point (e.g., haul truck 28, etc.) and/or the
excavator (e.g., mining shovel 10, etc.), the type of surface
underneath the deposit point and/or the excavator, or any other
number factors or conditions related to the digging operation. In
the illustrated embodiment of the FIGURES, the control system for
the mining shovel 10 is configured to prevent the dipper 12 from
emptying the dipper contents when the dipper 12 is above the dipper
height limit, thus preventing damage to the haul truck 28. It
should be noted that although the haul truck 28 is shown by way of
example in FIG. 3 and referred to throughout, the disclosure is
also applicable for use in conjunction with any other deposit point
for receiving dipper loads, including dump trucks, dumpsters,
conveyors, etc., all of which are intended to be within the scope
of this disclosure.
[0020] In an exemplary embodiment, the control system includes a
sensor assembly 36 for monitoring one or more factors or conditions
related to the operations of the mining shovel 10 (i.e., operating
conditions). The operating conditions of the mining shovel 10
(i.e., excavator) may include any factor or condition necessary or
useful for determining the dipper height limit, including any
condition related to the mining shovel 10, the deposit point,
and/or the surrounding environment. For instance, the sensor
assembly 36 may be configured to monitor a height of the dipper 12
or a dipper assembly relative to a surface (i.e., the deposit
point) in order to determine whether the dipper 12 is above or
below the dipper height limit. The sensor assembly 36 may also be
configured to monitor a weight of the dipper load, the shape or
position of the deposit point or another related machine or
component, the weather conditions in the area surrounding the
mining shovel 10, the condition of the ground or surface underneath
the mining shovel 10 and/or the deposit point, or any other factor
or condition necessary or useful for determining the dipper height
limit.
[0021] The sensor assembly 36 may be configured to monitor the
height of the dipper 12 relative to the deposit point in one or
more ways, depending on the suitability for the particular
application of the control system. For example, the sensor assembly
36 may be configured to directly measure the height of the dipper
12 relative to the deposit point by mounting one or more sensors to
the dipper 12 and pointing the sensors in the direction of the
deposit point. In other embodiments, the sensor assembly 36 may be
configured to monitor the height of the dipper 12 relative to a
base 40 of the mining shovel 10, relative to the boom assembly 22,
relative to another component of the mining shovel 10, or relative
to the ground, in order to calculate or estimate the distance
between the dipper 12 and the deposit point. In still other
embodiments, the sensor assembly 36 is configured to monitor or
measure the distance between the dipper 12 and another marker or
point in the surrounding area, such that the height of the dipper
12 relative to the deposit point can be calculated or
estimated.
[0022] In some embodiments, the sensor assembly 36 is centrally
located, having a single area in which the sensor assembly 36 is
positioned and/or mounted. For instance, the sensor assembly 36 may
be coupled to a single component of the mining shovel 10 (e.g., the
dipper 12, the boom assembly 22, the dipper arm 20, etc.), or
positioned in another location suitable for monitoring the relative
height of the dipper 12 and/or one or more other conditions related
to the mining shovel 10. In other embodiments, the sensor assembly
36 includes multiple elements having more than one location. For
instance, in one embodiment the sensor assembly 36 includes one or
more elements coupled to the dipper 12 (as shown in FIG. 1), one or
more elements coupled to a deposit point such as haul truck 28, and
one or more elements positioned in another location suitable for
monitoring one or more conditions related to the mining shovel
10.
[0023] In some embodiments, the sensor assembly 36 includes one or
more laser sensors (e.g., laser distance meters, laser
rangefinders, etc.) configured to monitor the height of the dipper
12. The laser sensors may be mounted on the dipper 12 and
configured to measure distances relative to the dipper 12. In an
exemplary embodiment, the laser sensors are configured to send one
or more laser pulses in the direction of the haul truck 28 in order
to measure a distance between the dipper 12 and the haul truck 28,
and thus determine a relative height of the dipper 12. In such an
embodiment, the laser pulse is reflected by a surface of the haul
truck 28 back in the direction of the laser sensors. The laser
sensors are configured to determine the distance between the dipper
12 and the haul truck 28 (i.e., the relative height of the dipper
12) based on the time taken by the pulse to be reflected off of the
truck bed 30 and returned to the laser sensors. The laser sensors
may be positioned on the dipper 12 such that a laser pulse is sent
in the direction of the truck bed 30 when the dipper 12 is in a
dumping or emptying position (i.e., when the dipper door 16 is
oriented at the bottom of the dipper 12 and facing the truck bed
30). Once the relative height of the dipper 12 is determined, the
laser sensors (e.g., sensor assembly 36) are configured to send one
or more signals to the control module 26 representing the time
taken to reflect the laser pulse and/or representing the relative
height of the dipper 12.
[0024] The sensor assembly 36 may also include one or more laser
scanners for monitoring the area surrounding the dipper 12. The
laser scanners are configured to emit one or more laser beams in
order to build a three-dimensional surface map (i.e.,
three-dimensional map) of the surrounding area. The laser scanners
may be rotatable, configured to rotate up to 360 degrees around a
single point while emitting one or more laser beams, or the laser
scanners may be stationary and include rotatable laser beams
configured to rotate up to 360 degrees around the stationary laser
scanner. In an exemplary embodiment, a laser scanner is mounted to
the dipper 12. In this embodiment, the laser scanner emits one or
more laser beams in all directions around the dipper 12, and the
beams are reflected off of the surrounding surfaces (e.g., the
ground, haul truck 28, other components of mining shovel 10, etc.),
back to the laser scanner. The laser scanner may be configured to
determine the distance between the dipper 12 and one or more
surrounding surfaces based on the time taken by the laser beam to
be reflected off of a surrounding surface and returned to the laser
scanner. In one embodiment, the sensor assembly 36 uses the
distances measured by the laser beams to build a three-dimensional
surface map of the area surrounding the dipper 12, sending one or
more signals representing the three-dimensional surface map to the
control module 26. In another embodiment, the sensor assembly 36
sends one or more signals representing the distances measured by
the laser beams to the control module 26, and the control module 26
is configured to build a three-dimensional surface map of the area
surrounding the dipper 12 using the signals. The laser scanner may
be configured to continuously emit laser beams so that the
three-dimensional surface map is continuously updated. The control
module 26 may use the three-dimensional surface map to determine a
relative height of the dipper 12, a distance between the dipper 12
and a surrounding surface, or another distance or height measured
by the laser scanner.
[0025] The sensor assembly 36 may also include one or more infrared
sensors configured to monitor a relative height of the dipper 12.
The infrared sensors may be positioned or coupled to the dipper 12
or another component of the mining shovel 10 and configured to
point in the direction of a deposit point or another surface in
order to measure the distance between the dipper 12 and the deposit
point (i.e., the relative height of the dipper 12). The infrared
sensors may then send one or more signals representing the relative
height of the dipper 12 to the control module 26, and the control
module 26 may utilize the signals to calculate or determine the
dipper height limit.
[0026] The sensor assembly 36 may also include one or more vision
sensors (e.g., cameras, video cameras, photosensors, etc.)
configured to monitor a relative height of the dipper 12. In an
exemplary embodiment, the vision sensors are coupled to the dipper
12 or to another component of the mining shovel 10. The vision
sensors are configured to capture an image of the deposit point in
order to monitor the distance between the dipper 12 and the deposit
point. The vision sensors may be configured to send one or more
signals to the control module 26 representing one or more measured
distances. The vision sensors may also be configured to determine a
distance between the dipper 12 and one or more components and/or
surfaces. The sensor assembly 36 may also include one or more GPS
sensors. The GPS sensors may be coupled to a component of the
mining shovel 10, coupled to a component of the deposit point, or
positioned in another location suitable for monitoring the distance
between the dipper 12 and the deposit point. The GPS sensors may be
configured to measure a distance between the dipper 12 and one or
more components or surfaces, and to send one or more signals to the
control module 26 representing the relative distance.
[0027] In one exemplary embodiment, the sensor assembly 36 may
include one or more position sensors (e.g., proximity sensors,
etc.) configured to monitor a relative height of the dipper 12. For
instance, position sensors may be coupled to the dipper arm 20 or
the boom assembly 22 in order to monitor the relative position of
the dipper arm 20 or boom assembly 22, and configured to send one
or more signals to the control module 26 representing the position
of the dipper arm 20, the boom assembly 22, and/or the dipper 12.
In an exemplary embodiment, the mining shovel 10 includes a
hydraulic cylinder (not shown) for crowding the dipper 12. In this
embodiment, a position sensor may be coupled to the hydraulic
cylinder (i.e., crowd cylinder) and configured to monitor the
relative position of the hydraulic cylinder. In some embodiments,
the position sensor sends one or more signals to the control module
26 representing the relative position of the monitored component
(e.g., dipper arm 20, boom assembly 22, hydraulic cylinder, etc.),
and the control module 26 is configured to calculate the relative
height of the dipper 12 from the signals. In other embodiments, the
position sensor may calculate or determine the relative height of
the dipper based on the relative position of the monitored
component, and send one or more signals to the control module 26
representing the relative height of the dipper 12.
[0028] In some embodiments, the control module 26 is configured to
calculate or determine the height of the dipper 12 relative to the
deposit point without the use of the sensor assembly 36. For
instance, the control module 26 may determine the height of the
dipper relative to the deposit point based on the position of the
boom assembly 22, the dipper arm 20, the cables 24, and/or another
component of the mining shovel 10. The control module 26 may also
be configured to determine the height of the dipper 12 relative to
the deposit point based on information or signals received from the
operator, such as through an operator interface 34 (e.g., wireless
communication device, control panel, etc.). In other embodiments,
the control module 26 is configured to calculate or determine the
height of the dipper 12 relative to the deposit point in another
manner suitable for the particular application of the load release
height control system.
[0029] In some embodiments, the sensor assembly 36 may include
weight sensors for monitoring the weight of the dipper load. The
weight sensors may be configured to monitor a weight of the dipper
load, and to send one or more signals to the control module 26
representing the weight of the dipper load. The control module 26
may be configured to use the signals from the weight sensors, as
well as signals or information regarding other relevant conditions
(e.g., type of material in the dipper load, type of deposit point,
etc.), to calculate the dipper height limit above which the emptied
dipper load may apply an excessive force to the deposit point. The
weight sensors may be coupled to the dipper 12, coupled to the
dipper arm 20, or mounted or positioned in another location on the
mining shovel 10 suitable for monitoring the weight of the dipper
load. In one embodiment, the weight sensors are connected to cables
24 which suspend the dipper arm 20 and dipper 12. In this
embodiment, the weight sensors are configured to measure the
tension in the cables 24 necessary to hold the dipper arm 20 and
the dipper 12 in place. The weight sensors may be configured to
determine the weight of the dipper load based on the measured
tension in the cables 24. The weight sensors may also be configured
to send one or more signals to the control module 26 representing
the tension in the cables 24, and the control module 26 may be
configured to calculate the weight of the dipper load from these
signals.
[0030] In an exemplary embodiment, the control module 26 is
configured to receive one or more signals from the sensor assembly
36, the signals representing one or more conditions of the mining
shovel 10 and/or the deposit point (i.e., operating conditions).
The control module 26 may also be configured to receive operator
input from the operator interface 34. The control module 26 may be
configured to use the signals and/or the operator input to
calculate or determine the dipper height limit. For instance, the
dipper height limit may be calculated based on some combination of
the weight of the dipper load, the height of the dipper 12 relative
to the deposit point, the type of material within the dipper 12,
the ground surface underneath the mining shovel 10 and/or the
deposit point, input received from the operator interface 34, or
any other relevant factors or conditions measured by the sensor
assembly 36 and/or the control module 26. In some embodiments, a
predetermined dipper height limit may be manually entered into the
control module 26 by an operator through the operator interface 34.
The control module 26 may also be configured to receive one or more
manually entered conditions or factors related to the mining shovel
10 from the operator interface 34, and to calculate or determine a
dipper height limit based on these manually entered conditions.
[0031] The control module 26 may be configured to utilize the
calculated or predetermined dipper height limit in order to prevent
damage to the deposit point from a dipper load released from an
excessive height (i.e., above the dipper height limit). In an
exemplary embodiment, the control module 26 is configured to
monitor the height of the dipper 12. In some embodiments, the
control module 26 is configured to prevent the dipper door 16 from
moving from the closed position to the open position (e.g., by
actuating or applying an interlock, etc.) when the dipper 12 is
above the dipper height limit, thus preventing the dipper 12 from
emptying its contents from an excessive height.
[0032] In some embodiments, the control module 26 is configured to
otherwise inhibit the movement of the dipper door 16 from the
closed position to the open position when the dipper 12 is above
the dipper height limit. For instance, in an exemplary embodiment
the dipper assembly includes snubbers or brakes (not shown) coupled
to the dipper door 16 and configured to slow the movement of the
dipper door 16 from the closed position to the open position. In
this embodiment, the control module 26 may be configured to control
the movement and/or actuation of the snubbers or brakes in order to
selectively slow the movement of the dipper door 16, reducing the
amount of material from the dipper load that is released from the
dipper 12 at any time, and thus reducing the force applied by the
dipper load to the deposit point at any time.
[0033] When the dipper 12 is above the dipper height limit, the
control module 26 may also be configured to provide one or more
audible, visual, or other sensory indications or warnings (e.g.,
tactile/audible feedback, warning light, noise, alarm, haptic
joystick, etc.) to the operator of the mining shovel 10, indicating
that the dipper contents may cause damage to the deposit point if
emptied.
[0034] In one exemplary embodiment, the control module 26 may be
configured to automatically position the dipper 12 based on the
signals received from the sensor assembly 36. For instance, if the
dipper 12 is positioned above the dipper height limit and the
operator attempts to move the dipper assembly to the actuated
position (i.e., release the dipper door 16) to empty the contents
of the dipper 12, the control module 26 may be configured to
automatically lower the dipper 12 until the dipper 12 is positioned
below the dipper height limit. The control module 26 may also be
configured to instruct the operator to manually lower the dipper 12
by the necessary amount so that the dipper 12 is positioned below
the dipper height limit before emptying the contents of the dipper
12.
[0035] Referring now to FIG. 5, a flow chart representation of the
load release height control system is shown, according to an
exemplary embodiment. In this embodiment, the control module 26 is
configured to receive signals representing operating conditions of
the mining shovel 10 (e.g., weight of the dipper load, height of
the dipper 12, ground conditions, type of material in dipper load,
deposit point conditions, weather conditions, etc.) from the sensor
assembly 36, as well as operator input (e.g., dipper height limit,
other operating conditions, etc.) from the operator interface 34
(e.g., wireless communication device, control panel, etc.). The
sensor assembly 36 may include laser sensors, vision sensors,
weight sensors, infrared sensors, GPS sensors, or other sensors or
components configured to monitor one or more operating conditions
of the mining shovel 10. In this embodiment, the control module 26
receives the signals and input, and determines whether the height
of the dipper 12 relative to the deposit point (i.e., surface) is
above the dipper height limit. If not, the control module 26 may
allow the dipper 12 to actuate or move to the actuated position to
empty the dipper load to the deposit point. If so, the control
module 26 may create a response such as a warning for the operator,
inhibit the movement of the dipper 12 to the actuated position,
and/or automatically lower the height of the dipper 12 below the
dipper height limit. The control module 26 may also be programmed
to calculate the dipper height limit based on the signals from the
sensor assembly 36 and the input from the operator interface
34.
[0036] The construction and arrangements of the load release height
control system for excavators, as shown in the various exemplary
embodiments, are illustrative only. Although only a few embodiments
have been described in detail in this disclosure, many
modifications are possible (e.g., variations in sizes, dimensions,
structures, shapes and proportions of the various elements, values
of parameters, mounting arrangements, use of materials, colors,
orientations, etc.) without materially departing from the novel
teachings and advantages of the subject matter described herein.
Some elements shown as integrally formed may be constructed of
multiple parts or elements, the position of elements may be
reversed or otherwise varied, and the nature or number of discrete
elements or positions may be altered or varied. The order or
sequence of any process, logical algorithm, or method steps may be
varied or re-sequenced according to alternative embodiments. Other
substitutions, modifications, changes and omissions may also be
made in the design, operating conditions and arrangement of the
various exemplary embodiments without departing from the scope of
the present invention.
INDUSTRIAL APPLICABILITY
[0037] The disclosed load release height control system for
excavators may be implemented into any machine having a dipper or
bucket for excavating material. The disclosed load release height
control system for excavators may prevent damage to deposit points
or surfaces such as haul trucks by preventing the excavator from
applying an excessive force to the deposit point. The disclosed
load release height control system may monitor the height of a
dipper or bucket for an excavator, preventing the dipper from
emptying its contents from above a dipper height limit, and thus
preventing the contents of the dipper from applying an excessive
force and damaging the deposit point.
[0038] It will be apparent to those skilled in the art that various
modifications and variations can be made to the disclosed load
release height control system for excavators. Other embodiments
will be apparent to those skilled in the art from consideration of
the specification and practice of the disclosed load release height
control system for excavators. It is intended that the
specification and examples be considered as exemplary only, with a
true scope being indicated by the following claims and their
equivalents.
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