U.S. patent application number 14/851927 was filed with the patent office on 2017-03-16 for control system for a rotating machine.
This patent application is currently assigned to Caterpillar Inc.. The applicant listed for this patent is Caterpillar Inc.. Invention is credited to Michael Brandt, Paul Friend, Robert Hamann, Paul E. Rybski, Mark M. Smith.
Application Number | 20170073925 14/851927 |
Document ID | / |
Family ID | 58236799 |
Filed Date | 2017-03-16 |
United States Patent
Application |
20170073925 |
Kind Code |
A1 |
Friend; Paul ; et
al. |
March 16, 2017 |
Control System for a Rotating Machine
Abstract
A system for controlling movement of a work implement of a
machine between a dump location and a plurality of dig locations
includes a rotatable implement system, and an implement system pose
sensor. A controller is configured to store first dig signals from
the implement system pose sensor indicative of a first dig
location, store second dig signals from the implement system pose
sensor indicative of a second dig location spaced from the first
dig location and store a dump location. The controller is further
configured to generate command signals to move the work implement
from the first dig location to the dump location, generate command
signals to dump a load of material carried by the work implement at
the dump location, and generate command signals to move the work
implement from the dump location to the second dig location.
Inventors: |
Friend; Paul; (Morton,
IL) ; Brandt; Michael; (Racine, WI) ; Hamann;
Robert; (Kenosha, WI) ; Rybski; Paul E.;
(Pittsburgh, PA) ; Smith; Mark M.; (Burlington,
WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Caterpillar Inc. |
Peoria |
IL |
US |
|
|
Assignee: |
Caterpillar Inc.
Peoria
IL
|
Family ID: |
58236799 |
Appl. No.: |
14/851927 |
Filed: |
September 11, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E02F 9/2041 20130101;
E02F 9/205 20130101; E02F 9/2054 20130101; E02F 3/439 20130101;
E02F 9/261 20130101 |
International
Class: |
E02F 3/43 20060101
E02F003/43; E02F 9/20 20060101 E02F009/20 |
Claims
1. A system for controlling movement of a work implement of a
machine between a dump location and a plurality of dig locations,
comprising: a rotatable implement system at a work site having a
linkage assembly including the work implement; an implement system
pose sensor for generating implement system pose signals indicative
of a pose of the implement system including a pose of the work
implement; and a controller configured to: store first dig signals
from the implement system pose sensor indicative of a first dig
location; store second dig signals from the implement system pose
sensor indicative of a second dig location, the second dig location
being spaced from the first dig location; store a dump location;
generate command signals to move the work implement from the first
dig location to the dump location; generate command signals to dump
a load of material carried by the work implement at the dump
location; and generate command signals to move the work implement
from the dump location to the second dig location.
2. The system of claim 1, wherein the controller is further
configured to store the first dig signals based upon positioning of
the work implement at the first dig location and actuation of an
input device.
3. The system of claim 2, wherein the controller is further
configured to store the second dig signals based upon positioning
of the work implement at the second dig location and actuation of
the input device.
4. The system of claim 1, wherein the controller is further
configured to store automatically the first dig signals upon
entering a learning mode and the work implement performing a
predetermined digging operation.
5. The system of claim 4, wherein the controller is further
configured to store automatically the second dig signals upon
entering the learning mode and the work implement performing a
second predetermined digging operation.
6. The system of claim 1, further including a rotatable base having
the linkage assembly mounted thereon, the linkage assembly
including a boom operatively connected to the base, a connecting
member operatively connected to the boom and the work
implement.
7. The system of claim 6, wherein the implement system pose sensor
includes sensors for determining a position of the linkage
assembly.
8. The system of claim 6, wherein the boom is fixedly mounted to
the base, and the work implement is fixedly mounted on the
connecting member.
9. The system of claim 8, wherein the connecting member is slidably
mounted on a saddle block and the saddle block is pivotably mounted
on the boom.
10. The system of claim 6, wherein the boom is pivotably mounted to
the base, and the work implement is pivotably mounted on the
connecting member.
11. The system of claim 10, wherein the connecting member is
pivotably mounted on the boom.
12. The system of claim 1, wherein the controller is further
configured to store an electronic map including the implement
system, the first dig location, the second dig location, and the
dump location in cylindrical coordinates.
13. The system of claim 1, further including a haul truck including
a haul truck pose sensor for generating truck pose signals
indicative of a pose of the haul truck, and the controller is
further configured to determine the dump location based upon the
pose of the haul truck.
14. The system of claim 1, wherein the controller is further
configured to store a second dump location, generate command
signals to move the work implement from the second dig location to
the second dump location, and generate command signals to dump a
load of material carried by the work implement at the second dump
location.
15. The system of claim 14, further including a second haul truck
including a second haul truck pose sensor for generating second
truck pose signals indicative of a pose of the second haul truck,
and the controller is further configured to determine the second
dump position based upon the pose of the second haul truck.
16. A controller implemented method for controlling movement of a
work implement of a machine between a dump location and a plurality
of dig locations, the work implement being operatively connected to
a rotatable implement system having a linkage assembly, the method
comprising: storing first dig signals from an implement system pose
sensor associated with implement system the indicative of a first
dig location; storing second dig signals from the implement system
pose sensor indicative of a second dig location, the second dig
location being spaced from the first dig location; storing a dump
location; generating command signals to move the work implement
from the first dig location to the dump location; generating
command signals to dump a load of material carried by the work
implement at the dump location; and generating command signals to
move the work implement from the dump location to the second dig
location.
17. The method of claim 16, further including storing the first dig
signals based upon positioning of the work implement at the first
dig location and actuating an input device.
18. The method of claim 16, further including storing automatically
the first dig signals upon entering a learning mode and the work
implement performing a predetermined digging operation.
19. The method of claim 16, further including storing a second dump
location, generating command signals to move the work implement
from the second dig location to the second dump location, and
generating command signals to dump a load of material carried by
the work implement at the second dump location.
20. A machine comprising: a rotatable base; a linkage assembly, the
linkage assembly including a boom operatively connected to the
base, a connecting member operatively connected to the boom, and a
material moving work implement operatively connected to the
connecting member; an implement system pose sensor for generating
implement system pose signals indicative of a pose of the implement
system including a pose of the work implement; and a controller
configured to: store first dig signals from the implement system
pose sensor indicative of a first dig location; store second dig
signals from the implement system pose sensor indicative of a
second dig location, the second dig location being spaced from the
first dig location; store a dump location; generate command signals
to move the work implement from the first dig location to the dump
location; generate command signals to dump a load of material
carried by the work implement at the dump location; and generate
command signals to move the work implement from the dump location
to the second dig location.
Description
TECHNICAL FIELD
[0001] This disclosure relates generally to controlling a machine
and, more particularly, to a control system for controlling
movement of a work implement while performing rotational material
moving operations.
BACKGROUND
[0002] Machines for moving material such as a rope shovels, mining
shovels, excavators, and backhoes may be configured for rotational
movement to move material between locations at a work site. For
example, machines with such rotational capabilities may dig
material at a first location such as a dig site with a material
engaging work implement and rotate the work implement to a second
location such as a dump site at which the work implement is dumped
or unloaded.
[0003] The machines may operate in an autonomous or semi-autonomous
manner to perform these tasks in response to commands generated as
part of a work plan for the machines. The machines may receive
instructions in accordance with the work plan to perform operations
at the work site, such as those related to mining, earthmoving,
construction, and other industrial activities.
[0004] The process of digging material at the first location and
dumping material at the second location may be repeated numerous
times over the course of a desired time period. Control of such
machines may be a complex task requiring a significant amount of
skill on the part of an operator and may require the manipulation
of multiple input devices. As an example, it is typically desirable
to move the work implement in a consistent and controlled manner
along the desired path between the first location and the second
location.
[0005] U.S. Pat. No. 5,968,104 discloses a hydraulic excavator
having an area limiting excavation control system. The area
limiting excavation control system has a setting device permitting
an operator to set an excavation area at which an end of a bucket
is allowed to move. The area limiting excavation control system
also includes angle sensors disposed at pivot points of a boom, an
arm, and a bucket for detecting respective rotational angles and
velocities thereof, a tilt angle sensor for detecting a tilt angle
of the excavator's body in a fore/aft direction, and a pressure
sensor for detecting a load pressure of the boom as it is moved
upward in response to signals generated by a control lever.
[0006] The foregoing background discussion is intended solely to
aid the reader. It is not intended to limit the innovations
described herein, nor to limit or expand the prior art discussed.
Thus, the foregoing discussion should not be taken to indicate that
any particular element of a prior system is unsuitable for use with
the innovations described herein, nor is it intended to indicate
that any element is essential in implementing the innovations
described herein. The implementations and application of the
innovations described herein are defined by the appended
claims.
SUMMARY
[0007] In one aspect, a system for controlling movement of a work
implement of a machine between a dump location and a plurality of
dig locations includes a rotatable implement system at a work site
having a linkage assembly and the work implement, and an implement
system pose sensor for generating implement system pose signals
indicative of a pose of the implement system including a pose of
the work implement. A controller is configured to store first dig
signals from the implement system pose sensor indicative of a first
dig location, store second dig signals from the implement system
pose sensor indicative of a second dig location spaced from the
first dig location and store a dump location. The controller is
further configured to generate command signals to move the work
implement from the first dig location to the dump location,
generate command signals to dump a load of material carried by the
work implement at the dump location, and generate command signals
to move the work implement from the dump location to the second dig
location.
[0008] In another aspect, a controller implemented method for
controlling movement of a work implement of a machine between a
dump location and a plurality of dig locations includes storing
first dig signals from an implement system pose sensor associated
with implement system the indicative of a first dig location,
storing second dig signals from the implement system pose sensor
indicative of a second dig location spaced from the first dig
location, and storing a dump location. The method further includes
generating command signals to move the work implement from the
first dig location to the dump location, generating command signals
to dump a load of material carried by the work implement at the
dump location, and generating command signals to move the work
implement from the dump location to the second dig location.
[0009] In still another aspect, a machine includes a rotatable
base, a linkage assembly including a boom operatively connected to
the rotatable base, a connecting member operatively connected to
the boom, and a material moving work implement operatively
connected to the connecting member, and an implement system pose
sensor for generating implement system pose signals indicative of a
pose of the implement system including a pose of the work
implement. A dump body has a lower surface defining an initial bed
height onto which material is dumped from the work implement and a
bed height sensor generates bed height signals indicative of a bed
height of the dump body. A controller is configured to store first
dig signals from the implement system pose sensor indicative of a
first dig location, store second dig signals from the implement
system pose sensor indicative of a second dig location spaced from
the first dig location and store a dump location. The controller is
further configured to generate command signals to move the work
implement from the first dig location to the dump location,
generate command signals to dump a load of material carried by the
work implement at the dump location, and generate command signals
to move the work implement from the dump location to the second dig
location.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 depicts a schematic view of a work site at which a
machine incorporating the principles disclosed herein may be
used;
[0011] FIG. 2 depicts a diagrammatic illustration of a machine in
accordance with the disclosure;
[0012] FIG. 3 depicts a diagrammatic illustration of a portion of
the machine of FIG. 2 dumping a load of material into a haul
truck;
[0013] FIG. 4 depicts a schematic view of a portion of the work
site of FIG. 1;
[0014] FIG. 5 depicts an exemplary graph of the portion of the work
site of FIG. 4 plotting the radius as a function of angle in
cylindrical coordinates;
[0015] FIG. 6 depicts an exemplary graph similar to FIG. 5 but
plotting the elevation as a function of angle in cylindrical
coordinates;
[0016] FIG. 7 depicts a diagrammatic illustration of a haul
truck;
[0017] FIG. 8 depicts an exemplary graph similar to FIG. 5 but
further depicting a stopping zone for the work implement and
auto-lift zones for certain obstacles;
[0018] FIG. 9 depicts an exemplary graph similar to FIG. 8 but
plotting the elevation is a function of angle in cylindrical
coordinates;
[0019] FIG. 10 depicts a schematic view similar to FIG. 4 but
utilizing a 2nd haul truck;
[0020] FIG. 11 depicts a schematic view similar to FIG. 4 but
utilizing a 2nd dig location;
[0021] FIG. 12 depicts a diagrammatic illustration of an excavator
and a haul truck in accordance with the disclosure;
[0022] FIG. 13 depicts a flowchart illustrating a material moving
process in accordance with the disclosure; and
[0023] FIG. 14 depicts a flowchart illustrating a further aspect of
the material moving process of FIG. 13.
DETAILED DESCRIPTION
[0024] FIG. 1 depicts a diagrammatic illustration of a work site
100 at which one or more machines 10 may operate. Work site 100 may
be a portion of a mining site, a landfill, a quarry, a construction
site, a roadwork site, a forest, a farm, or any other area in which
movement of machines is desired. As depicted, work site 100
includes an open-cast or open pit mine 101 having a face 102 from
which material may be excavated or removed by a machine 10 such as
a rope shovel 15 and loaded into a machine such as a haul truck 80.
The haul trucks 80 are depicted as traveling along a road 103 to
dump location at which the material is dumped. Machines 10 such as
dozers 95 may move material along a ground surface 104 near the
rope shovel 15 as well as near or towards a crest such as an edge
of a ridge 105, embankment, high wall or other change in elevation.
Face 102 and ground surface 104 may be collectively referred to
herein as a work surface.
[0025] Referring to FIG. 2, an exemplary rope shovel 15 is
depicted. Rope shovel 15 includes a platform or base 16 rotatably
mounted on an undercarriage or crawler 17. The crawler 17 may
include a ground engaging propulsion device such as a pair of
tracks 18 that operate to propel and turn the rope shovel 15. Base
16 may include a power unit, indicated generally at 19 and an
operator station 20. The power unit 19 provides or distributes
electric and/or hydraulic power to various components of the rope
shovel 15. A swing motor, indicated generally at 21, is operative
to control the rotation of the base 16 relative to the crawler 17
about axis 22.
[0026] A linkage assembly or implement system may be mounted on the
base 16 and includes a boom 25 having a lower or first end 26
operative connected, such as by being fixedly mounted, to the base
16. An A-frame 28 may be mounted on the based 16 and one or more
support cables 29 may extend between the A-frame and an upper or
second end 27 of the boom 25 to support the second end of the boom.
A pair of spaced apart sheaves 30 may be mounted on the second end
27 of the boom 25.
[0027] The linkage assembly may further include a material engaging
work implement such as a bucket or dipper 35 fixedly mounted to a
connecting member or dipper handle 40. Dipper 35 may include a
plurality of material engaging teeth 36 and a pivotable door 37
opposite the teeth to permit dumping or emptying of the dipper 35.
At a first closed position, the door 37 retains material in the
dipper 35 and at a second open position (FIG. 3), material may exit
the dipper through the door.
[0028] A hoist cable 45 extends from a hoist drum 46 on base 16, is
supported by sheaves 30 on the second end 27 of boom 25, and
engages a bail or padlock 38 associated with the dipper 35.
Extension or retraction of the hoist cable 45 through rotation of a
hoist motor, indicated generally at 47, lowers or raises the height
(i.e., the hoist) of the dipper 35 relative to a ground reference.
Material within the dipper 35 may be released by opening the door
37 of the dipper through the use of an actuator cable 48 that
extends between the door and an door actuator motor 49 on the base
16.
[0029] Dipper handle 40 is generally elongated and is operatively
connected to the boom 25. More specifically, the dipper handle 40
is slidably supported within saddle block 41 and the saddle block
is pivotably mounted on the boom 25. Extension or retraction (also
referred to as "crowd") of the dipper handle 40 may be controlled
by a crowd control mechanism operatively connected to the dipper
handle and the saddle block 41. In one embodiment, the crowd
control mechanism may include a double acting hydraulic cylinder 42
with one side of the hydraulic cylinder operatively connected to
the dipper handle 40 and the other side operatively connected to
the saddle block 41. The crowd of the dipper handle 40 may thus be
controlled by the operation of the hydraulic cylinder 42. In a
second embodiment (not shown), a crowd rope and a retract rope may
be operatively connected to the dipper handle and routed around a
crowd drum. Rotation of the crowd drum controls the crowd of the
dipper handle 40. In a third embodiment (not shown), a rack may be
mounted on dipper handle and a drive pinion mounted on the saddle
block. In the second embodiment, the crowd of the dipper handle 40
may be controlled by operation of the pinion.
[0030] Rope shovel 15 may include an operator station 20 that an
operator may physically occupy and provide input to control the
machine. The operator station 20 may include one or more input
devices (not shown) that an operator may utilize to provide input
to a control system, indicated generally at 55, to control aspects
of the operation of the rope shovel 15. The operator station 20 may
also include a plurality of display devices (not shown) to provide
information to an operator regarding the status of the rope shovel
15 and material moving operations.
[0031] Control system 55 may include an electronic control module
or controller 56 and a plurality of sensors. The controller 56 may
receive input signals from an operator operating the rope shovel 15
from within operator station 20 or off-board the machine through a
wireless communications system 110 (FIG. 1). The controller 56 may
control the operation of various aspects of the rope shovel 15
including positioning the dipper 35 and opening the door 37 of the
dipper to dump a load of material.
[0032] The controller 56 may be an electronic controller that
operates in a logical fashion to perform operations, execute
control algorithms, store and retrieve data and other desired
operations. The controller 56 may include or access memory,
secondary storage devices, processors, and any other components for
running an application. The memory and secondary storage devices
may be in the form of read-only memory (ROM) or random access
memory (RAM) or integrated circuitry that is accessible by the
controller. Various other circuits may be associated with the
controller 56 such as power supply circuitry, signal conditioning
circuitry, driver circuitry, and other types of circuitry.
[0033] The controller 56 may be a single controller or may include
more than one controller disposed to control various functions
and/or features of the rope shovel 15. The term "controller" is
meant to be used in its broadest sense to include one or more
controllers and/or microprocessors that may be associated with the
rope shovel 15 and that may cooperate in controlling various
functions and operations of the machine. The functionality of the
controller 56 may be implemented in hardware and/or software
without regard to the functionality. The controller 56 may rely on
one or more data maps relating to the operating conditions and the
operating environment of the rope shovel 15 and the work site 100
that may be stored in the memory of controller. Each of these data
maps may include a collection of data in the form of tables,
graphs, and/or equations.
[0034] The control system 55 and the controller 56 may be located
on the rope shovel 15 and may also include components located
remotely from the machine such as at a command center 111 (FIG. 1).
The functionality of control system 55 may be distributed so that
certain functions are performed at rope shovel 15 and other
functions are performed remotely. In such case, the control system
55 may utilize a communications system such as wireless
communications system 110 for transmitting signals between the rope
shovel 15 and a system located remote from the machine.
[0035] Rope shovel 15 may be equipped or associated with a
plurality of sensors that provide data indicative (directly or
indirectly) of various operating parameters of the machine. The
term "sensor" is meant to be used in its broadest sense to include
one or more sensors and related components that may be associated
with the rope shovel 15 and that may cooperate to sense various
functions, operations, and operating characteristics of the
machine.
[0036] A pose sensing system 60, as shown generally by an arrow in
FIG. 2, may include a pose sensor 61 to sense the position and
orientation (i.e., the heading, pitch, roll or tilt, and yaw) of
the rope shovel 15 relative to the work site 100. The position and
orientation of the rope shovel 15 are sometimes collectively
referred to as the pose of the machine.
[0037] The pose sensor 61 may include a plurality of individual
sensors that cooperate to generate and provide pose signals to
controller 56 indicative of the position and orientation of the
rope shovel 15. In one example, the pose sensor 61 may include one
or more sensors that interact with a positioning system such as a
global navigation satellite system or a global positioning system
to operate as a pose sensor. In another example, the pose sensor 61
may further include a slope or inclination sensor such as pitch
angle sensor for measuring the slope or inclination of the rope
shovel 15 relative to a ground or earth reference. The controller
56 may use pose signals from the pose sensors 61 to determine the
pose of the rope shovel 15 within work site 100. In other examples,
the pose sensor 61 may include a perception based system, or may
use other systems such as lasers, sonar, or radar to determine all
or some aspects of the pose of rope shovel 15.
[0038] If desired, the pose sensing system 60 may include distinct
position and orientation sensing systems. In other words, a
position sensing system (not shown) may be provided for determining
the position of the rope shovel 15 and a separate orientation
sensing system (not shown) may be provided for determining the
orientation of the machine.
[0039] One or more implement sensors may be provided to monitor the
position and status of the dipper 35. More specifically, sensors
may be provided to provide signals indicative of the position and
other characteristics of the dipper 35. A swing sensor 62 may be
provided that generates swing signals indicative of the angle of
the base 16 relative to the crawler 17. In one example, the pose
sensing system 60 may determine the pose of the base 16 and the
swing sensor 62 may determine the angle of the crawler 17 relative
to the base.
[0040] A hoist sensor 63 may be provided that generates hoist
signals indicative of the height of the dipper 35 relative to the
base 16. The hoist signals may be based upon the position of the
hoist cable 45, the hoist drum 46, and/or the hoist motor 47. A
door sensor 64 may be provided that generates door signals
indicative of the status (i.e., open or closed) of the door 37 of
the dipper 35. A crowd sensor 65 may be associated with the boom
25, dipper handle 40, and/or saddle block 41. The crowd sensor 65
may be configured to generate crowd signals indicative of the crowd
or position (i.e., the extension or retraction) of the dipper
handle 40 relative to the boom 25.
[0041] Each of the sensors may embody any desired structure or
mechanism. While described in the context of position sensors that
may be used to determine the relative positions of the base 16,
crawler 17, dipper 35, and dipper handle 40, some or all of the
sensors may use another frame of reference such as a global
navigation satellite system or a global positioning system. For
example, one or more sensors may be similar to the pose sensor 61
and determine positions relative to an earth or another non-machine
based reference.
[0042] Additional sensors may be provided on the rope shovel 15
including a weight or load sensor indicated generally at 66 for
determining the weight or load of material within the dipper 35,
one or more inertial measurement units or acceleration sensors
indicated generally at 67 for determining a rate of acceleration of
various components of the rope shovel, and one or more inclination
or pitch sensors 68 for determining the pitch of various components
of the machine. In addition to determining information regarding
the rope shovel 15 directly (e.g., by using acceleration sensor 67
to determine acceleration or using a pitch sensor 68 to determine
pitch), the sensors may be used to determine additional information
regarding the performance of the machine indirectly (e.g., by using
the acceleration sensor to determine velocity or the pitch sensor
to determine pitch rate).
[0043] The positions of the components of the rope shovel 15
including base 16, boom 25, dipper 35 and dipper handle 40 may be
determined based upon the kinematic model of the rope shovel
together with the dimensions of the base 16, crawler 17, dipper 35,
and dipper handle 40, as well as the relative positions between the
various components. More specifically, the controller 56 may
include a data map that identifies the position of each component
of the rope shovel 15 based upon the relative positions between the
various components. The controller 56 may use the dimensions and
the positions of the various components to generate and store
therein a three-dimensional electronic map of the rope shovel 15 at
the work site 100. In addition, by knowing the speed or
acceleration of certain components, the speed or acceleration of
other components of the rope shovel 15 may be determined.
[0044] The control system 55 may also include a terrain mapping
system 70 positioned on or associated with rope shovel 15 to scan
work site 100 and map the work surface surrounding the rope shovel
as well as any obstacles at the work site. The terrain mapping
system 70 may include one or more perception or perception sensors
71 (FIG. 4) that may scan work site 100 to gather information
defining the work surface thereof. More specifically, perception
sensors 71 may determine the distance and direction from the
perception sensors 71 to points that define a mapped surface such
as the work surface as well as obstacles at the work site 100. The
field of view of each perception sensor 71 is depicted
schematically at 72.
[0045] The obstacles may embody any type of object including those
that are fixed or stationary as well as those that are movable or
that are moving. Examples of fixed obstacles may include
infrastructure, storage, and processing facilities, buildings,
trees, and other structures and fixtures found at a work site 100.
Examples of movable obstacles may include machines such as haul
trucks 80, light duty vehicles (such as pick-up trucks and cars),
personnel, and other items that may move about work site 100.
[0046] Mapping or perception sensors 71 may be mounted on rope
shovel 15 such as at four corners of the machine as depicted in
FIG. 4. In other examples, perception sensors 71 may be mounted at
other locations on the rope shovel 15, on other machines, or
mounted in fixed locations at the work site 100. Perception sensors
71 may embody LIDAR (light detection and ranging) devices (e.g., a
laser scanner), RADAR (radio detection and ranging) devices, SONAR
(sound navigation and ranging) devices, cameras, and/or other types
of devices that may determine the range and direction to objects
and/or attributes thereof. Perception sensors 71 may be used to
sense the range, the direction, the color, and/or other information
or attributes about detected objects and the work surface and
generate mapping signals indicative of such sensed information and
attributes.
[0047] An object identification system, shown generally at 73, may
be mounted on or associated with the rope shovel 15 in addition to
the terrain mapping system 70. In some instances, the terrain
mapping system 70 and the object identification system 73 may be
integrated together. Object identification sensors 74 may generate
data that is received by the controller 56 and used by the
controller to determine the type of obstacles detected by the
object identification system 73. The object identification sensors
74 may be part of the perception sensors 71 and thus are depicted
schematically as the same components in FIG. 4. In an alternate
embodiment, the object identification sensors may be separate
components from the perception sensors 71.
[0048] The sensed data generated by the perception sensors 71 may
be used by the terrain mapping system 70 to generate an electronic
three-dimensional terrain map of the work site 100. The terrain map
may be overlaid or stored as a three-dimensional electronic map of
the work site 100 and include the three-dimensional map of the rope
shovel 15. In one example, the electronic map may be stored within
controller 56 and/or an offboard controller.
[0049] The data or data points defining the electronic map of the
work site 100 may be generated by the terrain mapping system 70 of
rope shovel 15, by one or more machines having a terrain mapping
system, or by a combination of the rope shovel and other machines.
Regardless of the manner in which the electronic map is initially
generated, data collected by the terrain mapping system 70 of the
rope shovel 15 and/or other machines having terrain mapping systems
may be subsequently used to update the electronic map.
[0050] Other or additional systems may be used to identify the
position or location of obstacles at the work site 100 and generate
data to be stored within the electronic map of the work site 100.
In one example, machines at the work site 100 may each include a
pose sensing system similar or identical to the pose sensing system
60 of rope shovel 15. For example, a plurality of haul trucks 80
may be operating at work site 100.
[0051] An example of a haul truck 80 is depicted in FIG. 7. Haul
truck 80 may include a frame 81 supported by one or more traction
devices 82 and a propulsion system for propelling the traction
devices. The propulsion system may include a prime mover, as shown
generally at 83, and a transmission (not shown) operatively
connected to the prime mover. Haul truck 80 may include a pivotable
dump body 84 into which material may be loaded and from which
material may be subsequently dumped. Referring to FIG. 4, dump body
includes a front wall 85, a rear wall 86, a lower surface 87, and a
pair of opposite sidewalls 88 that extend between and connect the
front and rear walls. A cab or operator station 89 may be included
that an operator may physically occupy and provide input to operate
the haul truck 80.
[0052] As with rope shovel 15, haul truck 80 may include a control
system 90 and a controller 91 similar to those of rope shovel 15
and the descriptions thereof are not repeated. Haul truck 80 may
include various systems and sensors for efficient operation of the
machine such as a pose sensing system 92 generally similar to that
of rope shovel 15 and a load sensing system generally indicated at
93 to sense the load or amount of material within the dump body
84.
[0053] The pose sensing system 92 of haul truck 80 may operate in a
manner similar to pose sensing system 60 of rope shovel 15. The
pose of the haul truck 80 may be communicated directly to the rope
shovel 15 or to a remote system and the information entered or
stored within the electronic map of the work site 100. Dimensions
of the haul truck 80 may be determined or communicated and an
electronic model of the truck may be added to the electronic map.
In one embodiment, identifying information such as a code may also
be transmitted from the haul truck 80 with the pose
information.
[0054] A data map within controller 56, either at rope shovel 15 or
at a remote location, may utilize the identifying code to determine
the dimensions of the haul truck 80 and generate an electronic
model of the haul truck based upon the pose of the truck and its
dimensions. In another embodiment, the identifying information that
accompanies the pose information may also include the dimensions of
the truck. In still another embodiment, the dimensions of each type
of machine that may be operating at the work site 100 may be stored
within controller 56. For example, a list of potential haul trucks
80 that may be operating at the work site 100 together with their
dimensions may be stored within controller 56. Upon determining
that an obstacle is within a predetermined distance or proximity of
the rope shovel 15, the object identification system 73 may
identify the type of haul truck and utilize its stored dimensions
to generate an electronic model that is stored within the
electronic map.
[0055] The electronic map may be configured in any desired manner.
In one example, the electronic map may be configured to store the
data in a cylindrical coordinate system with the central axis of
the cylindrical coordinate system corresponding to the axis 22 of
the rope shovel 15. For example, referring to FIG. 4, a portion of
work site 100 is depicted with rope shovel 15, haul truck 80, and
dozer 95 adjacent a face 102 of the open pit mine 101. In FIGS.
5-6, the rope shovel 15, haul truck 80, dozer 95, and face 102 of
FIG. 4 are depicted in a cylindrical coordinate system about axis
22 with the y-axis of FIG. 5 depicting the radius from the axis 22
and the y-axis of FIG. 6 depicting the elevation relative to a
ground surface 104. In both instances, the x-axis depicts the
position or angle about axis 22 and a horizontal position opposite
the dipper 35 corresponding to both zero and 360 degrees.
[0056] Comparing FIG. 4 to FIGS. 5-6, one-to-one correspondence
between many of the components, elements, or features of FIG. 4 may
be found. For example, face 102 of the mine 101 is depicted in both
FIGS. 5-6 and ground surface 104 is depicted as being slightly
above the x-axis in both FIGS. 5-6 for clarity. The outer limit 120
of the reach of dipper 35 is depicted in FIGS. 4-5 but not in FIG.
6.
[0057] Dipper 35 is spaced from the axis 22 and thus is depicted
above the x-axis in FIG. 5. Although not visible in FIG. 4, the
dipper 35 is elevated above the ground surface 104 and thus is
depicted in FIG. 6 above the ground surface.
[0058] Various obstacles adjacent the rope shovel 15 are also
depicted in FIGS. 5-6. Portions of the base 16 may contact
obstacles adjacent the rope shovel 15 while the rope shovel is
rotating about axis 22. In addition, in some instances, it may be
possible for the dipper 35 to contact the base 16. Accordingly, a
keep-out zone 121 corresponding to an outer path of travel of the
base 16 relative to axis 22 is depicted in FIGS. 4-5. The keep-out
zone 121 is not depicted in FIG. 6. The tracks 18 may also be
obstacles since it is possible for the dipper 35 to contact them
under certain circumstances. The tracks 18 are depicted in FIGS.
4-5 but not in FIG. 6.
[0059] Haul truck 80 includes portions that are obstacles and also
a portion that is a target zone for the dipper 35. More
specifically, the forward portion of the haul truck 80, including
the operator station 89, is depicted at 122. The rearward portion
123 of the haul truck may be divided into two sections with the
dump body 84 depicted as the target zone 124 and the remainder as
an obstacle 125. More specifically, the dump body 84 may be seen in
FIGS. 4-6 as being defined by front wall 85, rear wall 86, lower
surface 87, and sidewalls 88. As best seen in FIG. 5, the
cylindrical coordinate boundaries of the target zone 124 are
defined in one direction by sidewalls 88 that define the radial
boundary, and in a perpendicular direction by the front wall 85 and
rear wall 86 that define the circumferential boundary. The
elevation component of the target zone 124 is defined by the lower
surface 87 of the dump body 84 as well as the upper surfaces of the
each of the front wall, 85, rear wall 86, and sidewalls 88.
[0060] Dozer 95 is depicted in FIG. 5 as an obstacle spaced from
the axis 22 and has a height beginning at ground surface 104.
[0061] Rope shovel 15 may be configured to be operated
autonomously, semi-autonomously, or manually. When operating
semi-autonomously or manually, rope shovel 15 may be operated by
remote control and/or by an operator physically located within the
operator station 20. As used herein, a machine operating in an
autonomous manner operates automatically based upon information
received from various sensors without the need for human operator
input. As an example, a haul truck that automatically follows a
path from one location to another and dumps a load at an end point
may be operating autonomously. A machine operating
semi-autonomously includes an operator, either within the machine
or remotely, who performs some tasks or provides some input and
other tasks are performed automatically and may be based upon
information received from various sensors. As an example, a haul
truck that automatically follows a path from one location to
another but relies upon an operator command to dump a load may be
operating semi-autonomously. In another example of a
semi-autonomous operation, an operator may dump a dipper or bucket
of a rope shovel 15 or an excavator 200 (FIG. 12) into a haul truck
80 and a controller 56 may automatically return the dipper or
bucket to a position to perform another digging operation. A
machine being operated manually is one in which an operator is
controlling all or essentially all of the functions of the machine.
A machine may be operated remotely by an operator (i.e., remote
control) in either a manual or semi-autonomous manner.
[0062] Control system 55 may include a module or planning system,
indicated generally at 75 in FIG. 2, for determining or planning
various aspects of a material moving operation. The planning system
75 may utilize various types of inputs from the sensors associated
with the rope shovel 15 as well as the electronic map of the work
site 100 including the configuration of the work surface, the
position of the rope shovel, the position and movement of any
obstacles adjacent the rope shovel, desired or proposed dig
location(s), desired or proposed dump locations(s), and the
characteristics of the material to be moved. Capabilities and
desired operating characteristics and capabilities of the rope
shovel 15 as well as its kinematic model may also be stored within
controller 56 and used by the planning system 75. The planning
system 75 may simulate and evaluate any aspect of a material moving
operation, such as by evaluating a plurality of potential paths
between the current location of the dipper 35 and a target zone,
and then select (or provide feedback regarding) a proposed dig
location, dump location, and/or the path between the dig location
and the dump location that creates the most desirable results based
upon one or more criteria.
[0063] One example of a desired operating characteristic, the
controller 56 may be configured to minimize changes in direction
such as only moving each of the swing, crowd, and hoist of the
linkage assembly in a single direction during a material moving
cycle or operation. In another example of a desired operating
characteristic, the planning system 75 may be configured to avoid
passing over any obstacles at the work site, if possible. In other
words, while swinging the base 16 and the linkage assembly, the
planning system 75 may move the dipper 35 and dipper handle 40 to a
desired hoist and crowd, respectively, and continued to swing the
dipper over the dump body 84 while generally maintaining the hoist
until opening the door 37 of the dipper during the dumping
process.
[0064] The planning system 75 may be utilized regardless of whether
the rope shovel 15 is being operated autonomously,
semi-autonomously, or manually. When operating the rope shovel 15
manually, the planning system 75 may provide suggestions for dig
locations, dump locations, and paths therebetween. When operating
autonomously or semi-autonomously, the planning system 75 may
determine, and the controller 56 may generate, commands to direct
the dipper 35 to the desired location or in a desired manner such
as by controlling the rotation of the base 16 relative to the
crawler 17, the movement of the dipper handle 40 relative to the
boom 25, and the height of the dipper 35. Such commands may control
both the speed and acceleration (and deceleration) of each type of
movement of the rope shovel 15 (i.e., rotation, crowd, and
hoist).
[0065] In view of the size of the rope shovel 15 and the large
payloads that may be carried within the dipper 35, it may be
difficult or even impossible to stop the rope shovel quickly. For
example, rope shovel 15 may be a massive machine with a dipper 35
capable of carrying a payload of greater than 100 tons of material.
Accordingly, the planning system 75 may generate a stopping zone
126 (FIGS. 5-6) within the electronic map through which components
of the rope shovel 15 may travel by predicting the path or motion
of the rope shovel based upon its speed, acceleration, and mass
(including a payload) in the absence of additional inputs. In other
words, the stopping zone 126 may identify an anticipated path of
the machine based upon the machine's momentum.
[0066] The planning system 75 may also generate auto-lift zones
within the electronic map adjacent obstacles to provide an
additional safety factor. More specifically, an auto-lift zone may
be defined adjacent each obstacle so that if the dipper 35 or
dipper handle 40 enters the zone, the controller 56 may
automatically lift or raise the dipper in an attempt to raise the
dipper over the obstacle rather than it continuing into contact
with the obstacle. The size of each auto-lift zone may be a
function of the obstacle, the payload within the dipper 35, and the
velocity of the dipper. Referring to FIGS. 8-9, a first radial
auto-lift zone 130 is positioned on opposite sides of the dozer 95
and a first elevation auto-lift zone 131 is positioned on opposite
sides of the dozer.
[0067] If the dipper 35 approaches the dozer 95 from either
direction as the dipper is being swung, it will approach the first
radial auto-lift zone 130 (FIG. 8) and the controller 56 may
generate commands to cause the dipper to be raised. If the dipper
35 is higher than the first elevation auto-lift zone 131 (FIG. 9),
the dipper may pass over the dozer 95 without any action by the
controller 56 or an operator. It should be noted that the elevation
auto-lift zones are angled upward from the ground surface 104 since
the urgency of raising the dipper 35 may be a function of the
distance from the obstacle and the increase in elevation necessary
to avoid the obstacle.
[0068] A second radial auto-lift zone 132 is positioned on opposite
sides of the haul truck 80. An opening 133 extends partially
through the second radial auto lift zone 132 in alignment with the
dump body 84. A second elevation auto-lift zone 134 is positioned
on opposite sides of the haul truck 80 and is associated with one
of the second radial auto-lift zones 132 except along the opening
133. At the opening 133, a third elevation auto-lift zone 135 is
positioned on the left side of the haul truck as viewed in FIGS.
8-9.
[0069] If the dipper 35 approaches the haul truck 80 from the right
as viewed in FIGS. 8-9 as the dipper is being swung, it will
approach the second radial auto-lift zone 132 (FIG. 8) to the right
of the haul truck and the controller 56 may generate commands to
cause the dipper to be raised. If the dipper 35 is higher than the
second elevation auto-lift zone 134 (FIG. 9), the dipper may pass
over the haul truck 80 without any action by the controller 56 or
an operator.
[0070] If the dipper 35 approaches the haul truck 80 from the left
as viewed in FIGS. 8-9 as the dipper is being swung and it is above
the third elevation auto-lift zone 135 (FIG. 9) regardless of its
radial position, the dipper may pass over the haul truck 80 without
any action by the controller 56 or an operator. If the dipper 35
approaches the haul truck 80 from the left and is aligned with
either of the second radial auto-lift zones 132, the controller 56
may determine whether the dipper is above the third elevation
auto-lift zone 135. If the dipper is not above the third elevation
auto-lift zone 135, the controller 56 may generate commands to
cause the dipper to be raised.
[0071] If the dipper 35 approaches the haul truck 80 from the left
and is aligned with the opening 133, the controller 56 may
determine whether the dipper is above the fourth elevation
auto-lift zone 136. If the dipper is not above the fourth elevation
auto-lift zone 136, the controller 56 may generate commands to
cause the dipper to be raised.
[0072] In order to improve the material moving process (regardless
of whether it is being performed autonomously, semi-autonomously,
or manually), a re-spotting or re-positioning system, indicated
generally at 76 in FIG. 2, may be provided to identify instances in
which it is desirable to re-position a haul truck 80 prior to
dumping a load of material. For example, it may be desirable for
the dipper 35 to enter the space or target zone at the dump body 84
by moving over the rear wall 86 with the dipper at an angle and
between the sidewalls 88 as depicted in phantom in FIG. 3. Still
further, it may be desirable for a lower portion of the dipper 35
to travel or pass over the rear wall 86 but be positioned lower
than an upper surface of the sidewalls 88 as depicted in FIG. 3. As
such, the window or target into which it is desired to move the
dipper 35 may be relatively small.
[0073] In some instances it may be desirable to generally center
the dipper 35 between the front wall 85 and rear wall 86 of the
dump body but position the dipper closer to the sidewall closest to
the rope shovel 15 as depicted in FIGS. 10-11. Upon beginning the
dumping process, the controller 56 may generate commands to pull
the actuator cable 48 and also extend or crowd out the dipper
handle 40 to further increase the force applied to the actuator
cable. By positioning the dipper 35 closer to the sidewall 88
nearest the rope shovel 15, the dipper may be crowded out without
engaging the sidewall farthest from the rope shovel.
[0074] The re-positioning system 76 may be configured to analyze
the pose of a haul truck 80 and the pose and kinematic model or
capabilities of the rope shovel 15, as well as the location of any
additional obstacles at the work site 100, to determine whether the
dipper 35 may be efficiently and/or safely moved to the target zone
at the dump body 84 and dumped or whether it is desirable to
re-position of the haul truck prior to dumping. For example, the
controller 56 may determine a plurality of paths that the dipper 35
may travel from its current location (as determined by the pose of
the rope shovel 15) to the target zone at the dump body 84 based
upon the kinematic model of the implement system and the desired
operating characteristics of the implement system.
[0075] In one example, the haul truck 80 may be too close to the
base 16 of rope shovel 15 (i.e., within keep-out zone 121) so that
rotation of the base during the loading process would cause a
collision or the dipper 35 cannot be maneuvered into the desired
loading position generally centered between the front wall 85 and
rear wall 86 in a first direction and between the sidewalls 88 in a
second direction, with the second direction being generally
perpendicular to the first direction.
[0076] In another example, the haul truck 80 may be too far away
from the rope shovel 15 so that the dipper 35 may not be centered
relative to the dump body 84 even if the dipper handle 40 is fully
extended or crowded out (i.e., outside the outer limit 120 of the
reach of the dipper). In still another example, the haul truck 80
may be positioned too far forward or too far rearward and at an
angle such that the dipper 35 cannot enter the target zone or space
above the dump body 84 along the center of the rear wall 86 (FIG.
3).
[0077] In a further example, the haul truck 80 may be positioned at
a location in which the dipper 35 may be positioned as desired
above the dump body 84 but the haul truck is positioned at a
location relatively far from the dig location. In such case, it may
be desirable to re-position the haul truck 80 so that the time
spent by the rope shovel 15 swinging between the dig and dump
positions is reduced, thus increasing the efficiency of the
material loading process.
[0078] If the re-positioning system 76 analyzes the pose of the
haul truck 80 and the pose and kinematic model of the rope shovel
15 (or the pose of the boom 25) and determines that it is desirable
to re-position the haul truck 80, the operator of the haul truck
may be instructed to re-position the haul truck at a new location
or a new orientation.
[0079] In some instances, the re-positioning system 76 may be
configured to operate based upon the position or pose of any
portion of the implement system together with the kinematic model
of the implement system without the pose of the entire rope shovel
15 or even the pose of the dipper 35. In doing so, the controller
56 may determine the position or pose of a portion of the implement
system and determine all possible locations for the dipper 35 based
upon the position of the portion of the implement system. The
controller 56 may then analyze potential paths of the dipper 35 to
the target zone based for each of the possible locations of the
dipper 35 together with the kinematic model of the implement system
and the desired operating characteristics of the implement system.
For example, if the position of the boom 25 is known, the
controller 56 may determine all possible positions for the dipper
35 and the dipper handle 40. The controller may then determine
potential paths of the dipper 35 to the target zone based upon each
possible position of the dipper.
[0080] The instructions to re-position the haul truck 80 may take
any desired form. In one example, the instructions may be provided
as an alert command between the controller 56 of rope shovel 15 and
controller 91 of haul truck 80. The instructions may result in a
written communication on a display within the haul truck 80,
another type of visual indication such as flashing certain lights
of the haul truck, or an audible communication or indication such
as by generating a verbal request or sounding a horn or an alarm of
the haul truck. In another example, the rope shovel 15 may generate
an alert commands as visual or audible indications such as flashing
lights or sounding an alarm on the rope shovel.
[0081] When dumping or unloading a load of material from dipper 35,
in some instances, it may be desirable to position the dipper at a
specified or predetermined distance above the dump body 84 to
reduce or minimize the distance that material falls as it fills the
dump body. By reducing or minimizing distance that the material
falls, the impact of the material on the haul truck 80 is reduced,
which reduces wear on the haul truck 80 and fatigue on the truck
operator.
[0082] If the dipper 35 is positioned the predetermined distance
above the lower surface 87 of the dump body 84 when the dump body
is empty, as the dump body is filled with material, the dump height
of the dipper must be increased if it is desired to maintain the
relative dump height (i.e., the distance the material falls) to
compensate for the additional material. In other words, if it is
desirable to maintain a specified distance that the material falls
into the dump body 84, the height of the dipper 35 during the
dumping process must be sequentially increased after each dumping
cycle due to the addition of material into the dump body.
[0083] Referring to the height of the surface upon which the
material is being dumped as the bed height, the lower surface 87
may define the initial bed height. As each load of material is
added to the dump body 84, the additional material changes the
effective bed height (i.e., the height of the upper surface upon
which the next load may be dumped). Accordingly, to maintain the
desired relative dump height, it may be desirable to increase the
absolute position of the dipper 35 relative to the ground surface
104.
[0084] Control system 55 may include a dump height positioning
system, indicated generally at 77 in FIG. 2, that operates to
determine a desired height of the dipper 35 at which each dumping
or unloading operation should occur. The dump height positioning
system 77 may control the dump height when performing material
moving operations autonomously or semi-autonomously and may be used
to suggest a dump height when operating the rope shovel 15
manually.
[0085] In operation, the dump height positioning system 77 may
first determine the height of the lower surface 87 of the dump body
84 relative to ground surface 104. In one example, the perception
sensors 71 of the terrain mapping system 70 may be high enough to
determine the height of the lower surface 87 relative to the ground
surface 104 (i.e., the bed height). In another example, the
position of the lower surface 87 may be determined from the pose of
the haul truck 80 together with known machine dimensions such as
those associated with an identifying code for the haul truck as
discussed above.
[0086] After determining the height of the lower surface 87, the
dipper 35 may be moved to the desired position (i.e., at the
desired height above the lower surface and generally centered
relative to the dump body 84) and the door 37 of the dipper opened
to dump the material. The addition of material on top of the lower
surface 87 of dump body 84 will likely increase the effective bed
height. The dump height positioning system 77 may determine or
estimate a new effective bed height in any desired manner. In one
example using a closed loop system, the perception sensors 71 may
be utilized to determine the new effective bed height. In another
example using a closed loop system, additional mapping or
perception sensors, indicated generally at 79, may be provided at
the dipper 35 or dipper handle 40 and operate in a manner similar
to the perception sensors 71 to determine the effective bed
height.
[0087] In an example using an open loop system, the dump height
positioning system 77 may estimate the new effective bed height
based upon the dimensions or capacity of the dipper 35 and the
dimensions or capacity of the dump body 84 of haul truck 80. In a
further example using an open loop system, the dump height
positioning system 77 may estimate the new effective bed height by
raising the previous effective bed height by a predetermined
increment or distance.
[0088] Upon determining or estimating a new effective bed height, a
new dump height may be determined based upon the new effective bed
height and the relative dump height. The dipper 35 may be moved to
its desired position above the dump body 84 and the material dumped
into the haul truck 80. The process of determining or estimating a
new or subsequent effective bed height, a new or subsequent dump
height, and performing a material moving operation may be repeated
until the haul truck 80 is filled to the desired level.
[0089] It should be noted that in some instances, the dump height
positioning system 77 may determine a new dump height by raising
the previous dump height based upon the dimension of the dipper and
the dimensions of the dump body 84 rather than estimating a new
effective bed height by raising the previous effective bed height
by a predetermined increment and then calculating a new dump
height.
[0090] In another example, the dump height positioning system 77
may operate by determining a first or initial dump height based
upon the initial bed height and increasing the dump height by a
predetermined amount after each dump process until the dump body 84
is full. In one example, the predetermined amount that the dump
height is increased for each subsequent cycle may be generally
identical. In another example, the predetermined amount that the
dump height is increased for each subsequent cycle may be
different. In instances in which more than three dump cycles are
used for a haul truck 80, the predetermined distances may be
generally identical, different, or a combination.
[0091] Upon dumping each load of material, the rope shovel 15 may
be operated to return the dipper 35 to a desired dig location. This
process may be referred to as a return-to-dig process and may be
performed autonomously, semi-autonomously, or manually. When
operating autonomously or semi-autonomously, a return-to-dig
system, indicated generally at 78 in FIG. 2, may be configured to
move the dipper 35 sequentially between one or more dig locations
and one or more dump locations. The dig locations may be set
automatically, by an operator, or other personnel. In addition, the
desired sequence may be set automatically, by an operator, or other
personnel.
[0092] In one example depicted in FIG. 10, a material moving
operation may be configured with a single rope shovel 15 operating
at a single dig location 140 together with a first loading or dump
location 141 and a second loading or dump location 142 at which
haul trucks 80 may be loaded. The first dump location 141 and the
second dump location 142 may be positioned at any location but are
depicted in FIG. 10 on opposite sides of the rope shovel 15.
[0093] During a material loading operation, material may be loaded
into the dipper 35 at the dig location 140 and the dipper moved
into alignment with a first haul truck 80 located at the first dump
location 141 and unloaded. Upon emptying the dipper 35, the
controller 56 may generate command signals to move the dipper back
to the dig location 140 and the process of loading the first haul
truck 80 may be repeated until the first haul truck is fully
loaded.
[0094] Either before or while the rope shovel 15 is loading the
first haul truck 80, a second haul truck may be positioned at the
second dump location 142. Once the first haul truck 80 is fully
loaded, the first haul truck may depart the first dump location 141
and the dipper 35 returned to the dig location 140 to begin another
dipper loading and unloading cycle. After loading the dipper 35,
the dipper may be moved into alignment with the second haul truck
80 located at the second dump location 142 and unloaded. Upon
emptying the dipper 35, the dipper may be moved back to the dig
location 140 and the process of loading the second haul truck 80 is
repeated until the second haul truck is fully loaded. Either before
or while the rope shovel 15 is loading the second haul truck 80, an
empty haul truck may be positioned at the first dump location 141
and the loading process may be repeated at the first dump location
once the second haul truck is fully loaded. With the configuration
depicted in FIG. 10, the rope shovel 15 may be continuously
operated by positioning an empty haul truck 80 at either the first
dump location 141 or the second dump location 142 while the rope
shovel is loading a haul truck at the other dump location.
[0095] In a second example depicted in FIG. 11, a material moving
operation may be configured with a rope shovel 15 digging at both a
first dig location 145 and a second dig location 146 and dumping at
a single dump location 147. The first dig location 145 may be
located generally near or adjacent the dump location 147 and the
second dig location 146 located farther from the dump location.
[0096] During a material loading operation, material may be loaded
into the dipper 35 at the first dig location 145 and the dipper
moved into alignment with a haul truck 80 located at the dump
location 147 and unloaded. Upon emptying the dipper 35, the
controller 56 may generate command signals to move the dipper back
to the first dig location 145 and the process of loading the haul
truck 80 may be repeated until the haul truck is fully loaded. Once
the haul truck 80 is fully loaded, the haul truck may depart the
dump location 147 and an empty haul truck positioned at the dump
location.
[0097] While the loaded haul truck 80 is leaving the dump location
147 and the empty haul truck is being positioned at the dump
location, the dipper 35 may be moved to the second dig location 146
and material loaded into the dipper. The dipper 35 may be moved
back to the dump location 142 to fill the newly positioned empty
haul truck 80. Upon emptying the dipper 35, the dipper may be moved
to the first dig location 140 and the process of digging at the
first dig location and loading the haul truck 80 at the dump
location 147 may be repeated until the haul truck is fully loaded.
With the configuration depicted in FIG. 11, the time required to
move the fully loaded haul truck 80 from the dump location 147 and
position an empty haul truck thereat may be utilized more
efficiently by directing the rope shovel 15 to load the dipper 35
at the second dig location 146, which is located farther from the
dump location as compared to the first dig location 145.
[0098] In a further example, a configuration may be utilized that
is similar to that of FIG. 11 but includes a second dump location,
indicated generally at 148, near the second dig location 146. By
adding the second dump location 148, the rope shovel 15 may load a
haul truck at each dump location and then dig material at a dig
location near each dump location.
[0099] The positions of the dig locations may be set in any desired
manner. In one example, the dig locations may be set by an operator
manually moving the dipper to a desired location and actuating an
input device such as a switch (not shown) within the operator
station 20. The signals from the sensors (e.g., swing sensor 62 and
crowd sensor 65) indicative of the general position of the desired
dig location may be stored within controller 56 to subsequently
identify the desired dig location. The process may be repeated for
each dig location.
[0100] In another example, the desired dig locations may be set or
stored by entering the control system 55 into a learning mode and
an operator operating the rope shovel 15 to perform a digging
operation. Upon performing the digging operation, the controller 56
may determine the swing position from swing sensor 62 and the crowd
from crowd sensor 65 and store the positions to subsequently
identify the desired dig location.
[0101] In still another example, the desired dig locations may be
set or stored by identifying the locations on the electronic map
stored within controller 56. More specifically, an operator may
identify or input desired dig locations on a display device within
the operator station 20.
[0102] Referring to FIGS. 13-14, flowcharts of a semi-autonomous
material moving operation using rope shovel 15 is depicted. The
flowcharts depict a process in which an operator may manually
perform a digging operation and the controller 56 of rope shovel 15
semi-autonomously moves the dipper 35 into alignment with a haul
truck 80, dumps the load within the dipper, and returns the dipper
to a dig location at which the operator may perform a new digging
operation. At stage 150, characteristics of the machines operating
at the work site 100 may be entered into controller 56. The
characteristics may include operating capacities, dimensions,
desired operating characteristics, and other desired or necessary
information. Examples may include the kinematic model of the rope
shovel 15 and the dimensions of the haul trucks 80.
[0103] An electronic map of the work site 100 may be generated at
stage 151. In one example, the electronic map may be created by the
terrain mapping system 70. The perception sensors 71 may generate
mapping signals that are received by controller 56 and the
controller may convert the mapping signals into an electronic map
of the work site 100. The electronic map may include
representations that depict the positions of face 102, ground
surface 104, and the rope shovel 15. In addition, each of the
obstacles located by the terrain mapping system 70 and/or
identified by the object identification system 73 may be included
in the electronic map.
[0104] While the electronic map may be generated and stored in a
rectangular or Cartesian coordinate system, it may be desirable to
convert and/or store the electronic map in a cylindrical coordinate
system. Storing the electronic map in a cylindrical coordinate
system with the map centered about axis 22 may simplify the
generation of command signals by the controller 56, the operation
of the planning system 75, and the determination of whether a
portion of the rope shovel 15 is likely to come into contact with
an obstacle.
[0105] At stage 152, the controller 56 may determine the position
or pose of the target zone 124 including the height of the lower
surface 87 of the dump body 84 relative to ground surface 104 and
store the information within the electronic map of the controller
56. The position or pose of the target zone may be determined based
upon information from the terrain mapping system 70, the pose
sensing system 92, other mapping or perception systems, information
from a data map stored within any controller, and/or any other
desired systems.
[0106] Auto-lift zones around each obstacle may also be determined
and stored within the electronic map at stage 152.
[0107] One or more dig locations may be set or stored at stage 153
within controller 56. The dig locations may be identified and
stored within controller 56 in any desired manner. In one example,
an operator may move the dipper 35 to a desired dig location and
actuate an input device such as a switch (not shown) within the
operator station 20. Signals from the sensors (e.g., swing sensor
62, hoist sensor 63, and crowd sensor 65) indicative of the
position of the desired dig location may be stored within
controller 56.
[0108] At stage 154, the dipper 35 may be loaded with material such
as from the face 102 of the mine 101 (FIG. 1). It should be noted
that the operation of stages 153 and 154 may be reversed or may
occur simultaneously depending upon the manner in which the dig
location(s) are stored. The planning system 75 may plan at stage
155 a desired path to the dump location. More specifically, the
planning system 75 may determine the desired path for the dipper to
travel from to the target zone 124 at the dump body 84 of the haul
truck 80. Upon initially loading the dipper 35, the planning system
75 may determine the desired path from the dig location to the dump
location. As the dipper 35 moves towards the dump location, the
controller 56 may concurrently determine and update the desired
path of the dipper from its current location to the target zone
124.
[0109] While determining the path of the dipper 35, the controller
56 may also determine the stopping zone 126 of the dipper 35. Since
the stopping zone 126 is generally a function of the momentum of
the rope shovel 15, the length of the stopping zone will typically
increase as the rope shovel moves more rapidly. It should be noted
that by avoiding obstacles that are radially between the dipper 35
and the base 16, the likelihood of contact between an obstacle and
any portion of the rope shovel 15 is reduced.
[0110] The controller 56 may generate at stage 156 command signals
to move the dipper 35 along the identified or predetermined path
towards the target zone 124. While moving the dipper 35, the
controller 56 may receive at stage 157 data from the sensors
associated with the rope shovel 15 together with any sensors
associated with the obstacles and the work site 100 to update the
electronic map of the work site. Based upon the position, speed,
and acceleration of the rope shovel 15 as well as the obstacles
adjacent the rope shovel, the controller 56 may determine at
decision stage 158 whether the rope shovel is likely to make
contact with an obstacle as the dipper moved towards the target
zone 124.
[0111] If the rope shovel 15 is likely to contact an obstacle, the
controller 56 may determine at decision stage 159 (FIG. 14) whether
the obstacle is moving. If the obstacle is moving, the controller
56 may pause or wait at stage 160 for a predetermined period of
time in case the obstacle moves sufficiently out of the path of the
rope shovel 15. If the obstacle has moved sufficiently so that
contact or a collision between the rope shovel 15 and the obstacle
may be avoided, movement of the dipper 35 may be continued by
referring back to FIG. 13 at stage 155.
[0112] If the obstacle is not moving at decision stage 159 or has
not moved out of the path within the predetermined time period at
decision stage 161, controller 56 may determine at decision stage
162 whether movement of the rope shovel 15 may be stopped within a
sufficient distance or time period to avoid a collision with the
obstacle. If the rope shovel 15 may be stopped without a collision,
the controller 56 may generate commands to stop the machine at
stage 163. If the rope shovel 15 may not be stopped without a
collision, the controller 56 may generate commands at stage 164 to
raise the dipper 35 in an attempt to pass over the obstacle.
[0113] If the rope shovel 15 is not going to contact an obstacle,
the controller 56 may determine at decision stage 165 whether the
dipper 35 is sufficiently aligned with the target zone 124
including being positioned as desired at the dump body 84 and
positioned at the desired dump height above the lower surface 87 of
the dump body. If the dipper 35 is not sufficiently aligned with
the target zone 124 and at the desired dump height, the dipper may
continue to be moved towards the desired position and stages 155-8,
165 repeated.
[0114] If the dipper 35 is aligned with the target zone 124 and at
the desired dump height, the controller 56 may dump at stage 166
the load of material into the dump body 84. To do so, the
controller 56 may generate a command to actuate the door actuator
motor 49 which engages actuator cable 48 to open the door 37.
[0115] At stage 167, the controller 56 may determine the new
effective bed height of the dump body 84. To do so, the controller
56 may utilize perception sensors 71, additional sensors 79, an
estimate of the change in bed height due to the addition of
material into the dump body 84, or any other desired system or
process. At stage 168, the controller 56 may generate commands to
return the dipper 35 to a desired dig location and stages 154-168
repeated.
[0116] While the dipper 35 is being returned to the desired dig
location, the controller 56 may determine at decision stage 169
whether the haul truck 80 is fully loaded. In one embodiment, the
controller 56 may make such a determination based upon the analysis
of the new effective bed height of the dump body 84. In another
embodiment, a load sensing system 93 of haul truck 80 may be used
to determine when the haul truck is fully loaded. If the haul truck
80 is not fully loaded, the haul truck may remain in place and the
material moving process may be continued and stages 154-169
repeated.
[0117] If the haul truck 80 is fully loaded, the haul truck may be
moved at stage 170 from the dump location and transported to a
desired location spaced from the dump location. Once the fully
loaded haul truck 80 has been moved from the dump location, an
empty haul truck may be moved at stage 171 to the dump location and
the material moving process may be continued and stages 154-169
repeated.
[0118] Although described in the context of rope shovel 15, many of
the concepts disclosed herein are applicable to other similar
machines and systems. For example, FIG. 12 depicts an excavator 200
having multiple systems and components that may cooperate to move
material from a dig location to a dump location. Excavator 200 may
include a platform 201 rotatably disposed on undercarriage 202.
Undercarriage 202 may include one or more ground engaging drive
mechanism such as tracks 203.
[0119] Platform 201 may include a prime mover 204 operative to
power an implement system 205 including a work implement or tool
such as bucket 206. Prime mover 204 may provide a rotational output
to drive tracks 203, thereby propelling the excavator 200. Prime
mover 204 may also provide power to other systems and components of
the excavator 200.
[0120] The implement system 205 may include a boom 207, a
connecting member or stick 208, and a work implement or tool. A
first end of boom 207 may be pivotally connected to platform 201,
and a second end of the boom may be pivotally connected to a first
end of stick 208. The work implement or tool such as bucket 206 may
be pivotally connected to a second end of stick 208.
[0121] Rotation of platform 201 relative to undercarriage 202 may
be effected by a swing motor 210. Each linkage member may include
and be operatively connected to one or more actuators such as
hydraulic cylinders. More specifically, boom 207 may be propelled
by one or more boom hydraulic cylinders 211 (only one being shown
in FIG. 12). Stick 208 may be propelled by a stick hydraulic
cylinder 212. Rotation of the bucket 206 relative to the stick 208
may be effected by a work implement hydraulic cylinder 213.
[0122] Each of the swing motor 210, boom hydraulic cylinders 211,
stick hydraulic cylinder 212, and work implement hydraulic cylinder
213 may be driven by a hydraulic system, generally indicated at
214, that may be powered by the prime mover 204. Excavator 200 may
include a control system 215 and a controller 216 similar to those
of rope shovel 15.
[0123] Excavator 200 may also include systems and sensors for
efficient operation of the machine. Such systems and sensors may be
similar to or result in similar measurements and functionality to
the systems and sensors of rope shovel 15. As non-limiting
examples, the mapping system 70 of rope shovel 15 may be used with
excavator 200 to generate an electronic map of the work site 100
and store the electronic map within controller 216 in either
rectangular or cylindrical coordinates. Re-positioning system 76
may also be used with excavator 200 to identify instances in which
the excavator may not efficiently or safely load a haul truck 80
that is positioned near the excavator. In addition, dump height
positioning system 77 may be used with excavator 200 in instances
in which it is desired to control the height at which the bucket
206 is dumped. Finally, return-to-dig system 78 may be used with
excavator 200 in instances in which it is desired to utilize a
return-to-dig process that includes automated movement between a
plurality of either dig locations or dump locations.
[0124] From the forgoing, it may be understood that each of the
rope shovel 15 and the excavator 200 includes a base rotatably
mounted on an undercarriage having a ground engaging drive
mechanism. Each of the rope shovel 15 and the excavator 200 also
includes an implement system or linkage assembly mounted on the
base. Each implement system includes a boom secured to the base
although the boom 25 of the rope shovel is fixed while the boom 207
of the excavator is pivotably mounted to the base or platform 201.
Each of the rope shovel 15 and the excavator 200 further includes a
ground engaging work implement in the form of a dipper 35 or bucket
206, respectively. The dipper 35 is fixed to dipper handle 40 which
is operatively connected to the boom 25 while the bucket 206 is
pivotably mounted on the stick 208.
INDUSTRIAL APPLICABILITY
[0125] The industrial applicability of the systems described herein
will be readily appreciated from the foregoing discussion. The
present disclosure is applicable to many machines and tasks
performed by machines. Exemplary machines include rope shovels,
hydraulic mining shovels, excavators, and backhoes.
[0126] A re-positioning system 76 may be used to identify instances
in which the excavator may not efficiently or safely load a haul
truck 80 that is positioned near a machine such as rope shovel 15.
A dump height positioning system 77 may be used when it is desired
to control the height at which the bucket 206 is dumped. A
return-to-dig system 78 may be used when it is desired to move a
work implement such as dipper 35 from a dump location to one or
more dig locations in an automated manner.
[0127] It will be appreciated that the foregoing description
provides examples of the disclosed system and technique. However,
it is contemplated that other implementations of the disclosure may
differ in detail from the foregoing examples. All references to the
disclosure or examples thereof are intended to reference the
particular example being discussed at that point and are not
intended to imply any limitation as to the scope of the disclosure
more generally. All language of distinction and disparagement with
respect to certain features is intended to indicate a lack of
preference for those features, but not to exclude such from the
scope of the disclosure entirely unless otherwise indicated.
[0128] Recitation of ranges of values herein are merely intended to
serve as a shorthand method of referring individually to each
separate value falling within the range, unless otherwise indicated
herein, and each separate value is incorporated into the
specification as if it were individually recited herein. All
methods described herein can be performed in any suitable order
unless otherwise indicated herein or otherwise clearly contradicted
by context.
[0129] Accordingly, this disclosure includes all modifications and
equivalents of the subject matter recited in the claims appended
hereto as permitted by applicable law. Moreover, any combination of
the above-described elements in all possible variations thereof is
encompassed by the disclosure unless otherwise indicated herein or
otherwise clearly contradicted by context.
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