US20230383497A1 - Work machine with an adaptive control system and method for grade control - Google Patents
Work machine with an adaptive control system and method for grade control Download PDFInfo
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- US20230383497A1 US20230383497A1 US17/804,221 US202217804221A US2023383497A1 US 20230383497 A1 US20230383497 A1 US 20230383497A1 US 202217804221 A US202217804221 A US 202217804221A US 2023383497 A1 US2023383497 A1 US 2023383497A1
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Classifications
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02F—DREDGING; SOIL-SHIFTING
- E02F3/00—Dredgers; Soil-shifting machines
- E02F3/04—Dredgers; Soil-shifting machines mechanically-driven
- E02F3/76—Graders, bulldozers, or the like with scraper plates or ploughshare-like elements; Levelling scarifying devices
- E02F3/80—Component parts
- E02F3/84—Drives or control devices therefor, e.g. hydraulic drive systems
- E02F3/844—Drives or control devices therefor, e.g. hydraulic drive systems for positioning the blade, e.g. hydraulically
- E02F3/847—Drives or control devices therefor, e.g. hydraulic drive systems for positioning the blade, e.g. hydraulically using electromagnetic, optical or acoustic beams to determine the blade position, e.g. laser beams
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02F—DREDGING; SOIL-SHIFTING
- E02F3/00—Dredgers; Soil-shifting machines
- E02F3/04—Dredgers; Soil-shifting machines mechanically-driven
- E02F3/76—Graders, bulldozers, or the like with scraper plates or ploughshare-like elements; Levelling scarifying devices
- E02F3/7609—Scraper blade mounted forwardly of the tractor on a pair of pivoting arms which are linked to the sides of the tractor, e.g. bulldozers
- E02F3/7613—Scraper blade mounted forwardly of the tractor on a pair of pivoting arms which are linked to the sides of the tractor, e.g. bulldozers with the scraper blade adjustable relative to the pivoting arms about a vertical axis, e.g. angle dozers
Abstract
An adaptive control system automatically controls an attachment position during a grading operation of a surface. The system comprises a frame, an attachment, first sensor, a second sensor, a laser receiver and a controller. The first sensor generates a first sensor signal indicative of an angle of the frame. The second sensor generates a second sensor signal indicative of an angle of the ground-engaging attachment. The laser receiver receives a laser signal from a laser beacon and generates a height signal based on the laser signal. The height signal is indicative of a position of either the attachment or the frame relative to the laser signal. The controller establishes a target grade based on a desired grade of the surface; identifies a position of the attachment; receives the first sensor signal; the second sensor signal; and the laser signal. The controller generates a first control signal or second control signal based on the inputs.
Description
- The disclosure generally relates to an adaptive control system and method for a work machine with grade control.
- Grading operations with work machines is a specialized phase of the construction process. Proper ground preparation ensures expected outcomes in architectural construction, control of water runoff, road construction, environmental impact and compliance with land grading standards. When using laser grading systems, objects may temporarily disrupt communications between a laser beacon located external to the work machine and the laser receiver on a work machine. Therein lies an opportunity for improved grade control for continued performance.
- An adaptive control system and method for a work machine is disclosed. The adaptive control system automatically controls an attachment position during a grading operation of a surface. The system comprises a frame, an attachment, first sensor, a second sensor, a laser receiver and a controller. The first sensor is configured to generate a first sensor signal indicative of an angle of the frame relative to the direction of gravity. The second sensor is configured to generate a second sensor signal indicative of an angle of the ground-engaging attachment relative to one of the frame and the direction of gravity. The laser receiver is configured to receive a laser signal from a laser beacon. The laser receiver generates a height signal based on the laser signal wherein the height signal is indicative of a position of either the attachment or the frame relative to the laser signal. The controller has a non-transitory computer readable medium with a program instruction to grade the surface. The program instructions when executed causes a processor of the controller to establish a target grade based on a desired grade of the surface; identify a position of the attachment with respect to the frame, the surface, or the laser signal; receive the first sensor signal from the first sensor; receive the second sensor signal from the second sensor; and receive the laser signal from the laser beacon. The processor may generate a first control signal based on the height signal. The first control signal actuates the + to maintain the attachment at a position corresponding to the target grade as the work machine propels. The processor may generate a second control based on either the first sensor signal or the second sensor signal in the absence of the height signal. The second control signal causing one or more actuators coupling the attachment to the work machine to maintain the attachment at a position corresponding to the historical value of a grade profile of the attachment as the work machine propels.
- The laser receiver may comprise of a first receiver and a second receiver, wherein each receiver is located on a first laser mast and a second laser mast, respectively. The laser mast extends upwardly from a location fixed relative to the frame. The first receiver and the second receiver create a first height signal and a second height signal, respectively. The first height signal and the second height signal enable the controller to calculate the grade profile of the attachment. In the absence of either the first height signal or the second height signal, the controller may generate a third control signal based on the first sensor signal, the second sensor signal, and the remaining height signal.
- The historical value may be derived in various ways. In a first embodiment, the running average is derived from a predetermined period of time. In a second embodiment, the running average is derived from a predetermined tolerance band. In a third embodiment, the running average is derived from a predetermined number of passes. In a fourth embodiment, the running average is based on a sampling rate dependent on either a worksite condition or a job function.
- The processor may further be configured to create a performance degradation alert signal for the grading operation after a predetermined period of time of the second control signal operating the one or more actuators.
- The processor may further be configured to suspend auto control mode of maintaining the attachment for the grading operation after a predetermined time of the second control signal operating the one or more actuators.
- The height signal automatically controls the height of the laser receiver to correspond to the height of the laser signal as the work machine propels.
- The method of automatically controlling a position of an attachment on a work machine during a grading operation of a surface includes the following steps. In a first step, the method includes establishing a target grade to establish a desired grade of the surface. Next, the method includes identifying a position of the attachment with respect to one of the frame, the surface, and the laser signal. The method also includes receiving a first sensor signal from a first sensor, receiving a second sensor signal form a second sensor, receiving a laser signal from a laser beacon, and generating a height signal based on the laser signal received wherein the height signal is indicative of a position of one of the attachment and the frame relative to the laser signal. The first sensor signal is indicative of an angle of the frame relative to the direction of gravity. The second sensor signal is indicative of an angle of the ground-engaging attachment relative to one of the frame and the direction of gravity. The method then includes generating a first control signal based on the height signal wherein the first control signal causing one or more actuators coupling the attachment to the work machine to maintain the attachment at a position corresponding to the target grade as the work machine propels. The method then includes generating a second control signal based on one of the first sensor signal and the second sensor signal in the absence of the height signal. The second control signal operating the one or more actuators to maintain the attachment at a position corresponding to historical value a grade profile as the work machine propels.
- The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the best modes for carrying out the teachings when taken in connection with the accompanying drawings.
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FIG. 1 is a side view of one embodiment of a work machine, shown as a skid steer. -
FIG. 2 is a block diagram of the system architecture and the flow of the adaptive grade control system. -
FIG. 3 is a flowchart of a method of automatically controlling an attachment on a work machine with the adaptive control system for grade control. -
FIG. 4 is a logic flow diagram illustrating one embodiment of the adaptive control system for grading. - Those having ordinary skill in the art will recognize that terms such as “above,” “below,” “upward,” “downward,” “top,” “bottom,” etc., are used descriptively for the figures, and do not represent limitations on the scope of the disclosure, as defined by the appended claims. Furthermore, the teachings may be described herein in terms of functional and/or logical block components and/or various processing steps. It should be realized that such block components may be comprised of any number of hardware, software, and/or firmware components configured to perform the specified functions.
- Terms of degree, such as “generally”, “substantially” or “approximately” are understood by those of ordinary skill to refer to reasonable ranges outside of a given value or orientation, for example, general tolerances or positional relationships associated with manufacturing, assembly, and use of the described embodiments.
- In addition, as used herein, the term “or” is an inclusive “or” operator and is equivalent to the term “and/or,” unless the context clearly dictates otherwise. The term “based on” is not exclusive and allows for being based on additional factors not described, unless the context clearly dictates otherwise.
- As used herein, unless otherwise limited or modified, lists with elements that are separated by conjunctive terms (e.g., “and”) and that are also preceded by the phrase “one or more of” or “at least one of” indicate configurations or arrangements that potentially include individual elements of the list, or any combination thereof. For example, “at least one of A, B, and C” or “one or more of A, B, and C” indicates the possibilities of only A, only B, only C, or any combination of two or more of A, B, and C (e.g., A and B; B and C; A and C; or A, B, and C).
- As used herein, “controller” 10 is intended to be used consistent with how the term is used by a person of skill in the art, and refers to a computing component with processing, memory, and communication capabilities, which is utilized to execute instructions (i.e., stored on the
memory 20 or received via the communication capabilities) to control or communicate with one or more other components. In certain embodiments, thecontroller 10 may be configured to receive input signals in various formats (e.g., hydraulic signals, voltage signals, current signals, CAN messages, optical signals, radio signals), and to output command or communication signals in various formats (e.g., hydraulic signals, voltage signals, current signals, CAN messages, optical signals, radio signals). - The
controller 10 may be in communication with other components on thework machine 100, such as hydraulic components, electrical components, and operator inputs within an operator station of an associated work machine. Thecontroller 10 may be electrically connected to these other components by a wiring harness such that messages, commands, and electrical power may be transmitted between thecontroller 10 and the other components. Although thecontroller 10 is referenced in the singular, in alternative embodiments the configuration and functionality described herein can be split across multiple devices using techniques known to a person of ordinary skill in the art. Thecontroller 10 includes the tangible,non-transitory memory 20 on which are recorded computer-executable instructions, including an adaptive control algorithm. Theprocessor 30 of thecontroller 10 is configured for executing theadaptive control algorithm 40. - The
controller 10 may be embodied as one or multiple digital computers or host machines each having one or more processors, read only memory (ROM), random access memory (RAM), electrically-programmable read only memory (EPROM), optical drives, magnetic drives, etc., a high-speed clock, analog-to-digital (A/D) circuitry, digital-to-analog (D/A) circuitry, and any required input/output (I/O) circuitry, I/O devices, and communication interfaces, as well as signal conditioning and buffer electronics. - The computer-
readable memory 20 may include any non-transitory/tangible medium which participates in providing data or computer-readable instructions. Thememory 20 may be non-volatile or volatile. Non-volatile media may include, for example, optical or magnetic disks and other persistent memory. Example volatile media may include dynamic random-access memory (DRAM), which may constitute a main memory. Other examples of embodiments formemory 20 include a floppy, flexible disk, or hard disk, magnetic tape or other magnetic medium, a CD-ROM, DVD, and/or any other optical medium, as well as other possible memory devices such as flash memory. - As such, a
method 300 may be embodied as a program oralgorithm 40 operable on thecontroller 10. It should be appreciated that thecontroller 10 may include any device capable of analyzing data from various sensors, comparing data, making decisions, and executing the required tasks. - Referring now to the drawings,
FIG. 1 illustrates a side view of awork machine 100, depicted as a skid steer with anattachment 105 operatively coupled to thework machine 100. It should be understood, however, that thework machine 100 could be one of many types of work machines, including, and without limitation, a skid steer, a backhoe loader, a front loader, a bulldozer, and other construction or agricultural vehicles with a grading capacity. Thework machine 100, as shown, has aframe 110, having a front-end section, or portion, and a rear-end portion 125. Thework machine 100 includes a ground-engagingmechanism 155 that supports theframe 110 and anoperator cab 160 supported on theframe 110. Theoperator cab 160 is optional if the cab is operated remotely and/or autonomously. The ground-engagingmechanism 155 may be configured to support theframe 110 on asurface 135. Thework machine 100 may be operated to engage the ground and cut and move material to achieve simple or complex ground features on the ground. As used herein, direction with regards to the work machine is the direction such as operator faces. The work machine may experience movement in three directions and rotation in three directions. Direction for the work machine may also be referred to with regard tolongitude 45 or the longitudinal directions,latitude 50 or the lateral direction, and vertical 55 of the vertical direction. Rotations for the work machine may be referred to roll or theroll direction 60,pitch 65 or the pitch direction, andyaw 70 or the yaw direction or heading. - A power source is coupled to the
frame 110 and is operable to move thework machine 100. The illustratedwork machine 100 includes wheels, but other embodiments may include one or more tracks or wheels that engage thesurface 135. In this exemplary embodiment, the ground-engagingmechanism 155 on the left side of thework machine 100 may be operated at a different speed, or in a different direction, from the ground-engagingmechanism 155 on the right side of thework machine 100. - Now referring to both
FIGS. 1 and 2 , thework machine 100 comprises theboom assembly 170 coupled to theframe 110. The attachment 105 (may also be referred to as work tool) may be coupled at a forward portion of the boom assembly 170 (e.g. a blade) while the rear portion of theboom assembly 170 is pivotally coupled to theframe 110. Theattachment 105 at the forward portion of theboom assembly 170 may be coupled through an attachment coupler (not shown), an industry standard configuration or a coupler universally applicable to many Deere attachments and several after-market attachments. - The
boom assembly 170 of the exemplary embodiment, comprises a first pair of boom arms 175 (one each on a left side and a right side) pivotally coupled to theframe 110 and moveable relative to theframe 110 by a pair of boom hydraulic actuators (not shown). During a grading operation, theboom arms 175 remain stationary. The attachment coupler is coupled to a forward section of theboom arms 175 and are moveable relative to theframe 110 by a pair of pitch/lift actuators 185. Theframe 110 of thework machine 100 further comprises an auxiliary port on the front-end portion of the work machine to couple one or more auxiliary hydraulic actuators (i.e. hydraulic actuators found on the attachment) to drive movement of or actuate auxiliary functions of an attachment. The attachment coupler (not shown) enables the mechanical coupling of theattachment 105 to theframe 110. Theauxiliary port 195, contrary to the attachment coupler, enables the hydraulic coupling of anglinghydraulic actuators 198 on theattachment 105 to the hydraulic system. The anglinghydraulic actuators 198 on the attachment 105 (e.g. a dozer blade) includes a single tilthydraulic actuator 187 and a pair of anglinghydraulic actuators 198. The tilthydraulic actuator 187 tilts theattachment 105 relative to thework machine 100, which may also be referred to as moving theattachment 105 in the direction ofroll 60. That is, actuating the angling hydraulic actuators 198 (more specifically the tilt hydraulic actuator 187) actuates the attachment and tilts the attachment in a radial motion about the forward portion of theboom assembly 170. The pair of anglinghydraulic actuators 198 allow for theattachment 105 to move in the direction ofyaw 70 or angle the attachment 1050 relative to theframe 110 in the direction ofyaw 70. -
FIG. 2 is a block diagram of the system architecture of the work machine and the flow of the adaptive control system 200 for grade control. One known system for grade control is available from Deere & Company of Moline, Ill. as an Integrated Grade Control (IGC) system, which generally is a blade control system using the combination of sensor input (e.g. GPS) and stored data (e.g. maps). The IGC system may also allow for operator control of an initial position setting, such as an initial height of a blade attachment. The IGC system may also allow for a combination of operator and automated position control. For example, the angle of the blade attachment may be initially or continuously under the control of the operator via a user interface, and the tilt of the blade may be controlled automatically according to input from sensors and data storage. - The adaptive grade control system comprises a
first sensor 205, asecond sensor 210, a laser receiver 215, and acontroller 10. Thefirst sensor 205 is affixed to theframe 110 of thework machine 100 and configured to provide a first sensor signal 220 indicative of the movement and orientation of theframe 110. In alternative embodiment, thefirst sensor 205 may not be affixed directly to theframe 110 but instead be connected to the frame through intermediate components or structures. In these alternative embodiment, thefirst sensor 205 is not directly affixed to theframe 110 but is still connected to the frame at a fixed relative position so as to experience the same motion as theframe 110. Thefirst sensor 205 is configured to generate a first sensor signal 220 indicative of an angle of the frame relative to the direction of gravity, an angular measurement in the direction ofpitch 65. This first sensor signal 220 may be referred to as a frame inclination signal. Thecontroller 10 may actuate an implement based on the frame inclination angle. Thefirst sensor 205 may also be configured to provide a first sensor signal 220 or signals indicative of other positions or velocities of theframe 110, including, its angular position, velocity, or acceleration in a direction such as the direction ofroll 60,pitch 65,yaw 70 or its linear acceleration in a direction such as the direction oflongitude 45,latitude 50, and vertical 55. Thefirst sensor 205 may be configured to directly measure inclination, measure angular velocity and integrate to arrive at inclination, or measure inclination and derive to arrive at angular velocity. - The
second sensor 210 may provide a blade inclination signal, which indicates the angle of the blade relative to gravity 220. Thesecond sensor 210 is configured to generate a second sensor signal 225 indicative of an angle of the ground-engagingattachment 105 relative to one of theframe 110 and the direction of gravity. Thesecond sensor 210 is affixed to the attachment 105 (shown here as an exemplary embodiment as a blade). Thesecond sensor 205, like thefirst sensor 205, may be configured to measure angular position (inclination or orientation), velocity, or acceleration, or linear acceleration. In alternative embodiments, thesecond sensor 210 may be configured to instead measure an angle of linkage, such as an angle between theboom assembly 170 and theframe 110, in order to determine a position of theattachment 105. In alternative embodiments, thesecond sensor 210 may not be directly affixed to theattachment 105 but may instead be connected to theattachment 105 through intermediate components or structures. In these alternative embodiments, thesecond sensor 210 is not directly affixed to theattachment 105 but is still connected to the attachment at a fixed relative position so as to experience the same motion as the attachment. - The laser receiver 215 is configured to receive a
laser signal 235 from alaser beacon 237. The laser receiver 215 generates a height signal 240 based on thelaser signal 235, wherein the height signal 240 is indicative of a position of one of theattachment 105 and theframe 110 relative to thelaser beacon 237. Located on alaser mast 115 and by detecting thelaser signal 235 from thelaser beacon 237, the laser receiver 215 may be configured to monitor the height of thework machine 100 relative to thelaser beacon 237. In one exemplary embodiment, thelaser beacon 237 may be configured to deliver alaser signal 235 such as a low intensity laser beam that may be swept over a worksite to define a laser plane. Thelaser beacon 237 may be positioned at a preselected coordinate location with the worksite 245. The laser beam may define the laser plane above the worksite at a predetermined elevational position, with the laser plane being substantially parallel to a desired surface grade. The distance between the laser plane and the target grade may thereby establish an elevational coordinate position in thevertical direction 55. - The
controller 10 has a non-transitory computer readable medium with aprogram instruction 40 to grade thesurface 135 wherein theprogram instructions 40 when executed causes aprocessor 30 of thecontroller 10 to perform the following steps. Theprocessor 30 will establish atarget grade 305 based on a desired grade of thesurface 135, and then identify a position of theattachment 105 with respect to one of theframe 110, thesurface 135, and thelaser signal 235. Theprocessor 30 may then receive the first sensor signal 220 from thefirst sensor 205, receive the second sensor signal 225 from thesecond sensor 210, and receive thelaser signal 235 from thelaser beacon 237. Theprocessor 30 may then generate afirst control signal 335 based on the height signal 240 wherein thefirst control signal 335 causing one ormore actuators 197 coupling the attachment to the work machine to maintain theattachment 105 at a position corresponding to thetarget grade 305 as thework machine 100 propels about a worksite 245. In the disclosed embodiment, the one ormore actuators 197 comprises of the pitch or liftactuators 185, tilthydraulic actuators 187, and anglinghydraulic actuators 198. Other machines may include a different set of actuators coupling the attachment to the work machine, for operating linkage kinematics. - In the absence of the height signal 240, the
processor 30 may generate asecond control signal 340 based on one of the first sensor signal 220 and the second sensor signal 225 wherein thesecond control signal 340 causing one ormore actuators 197 coupling the attachment to the work machine to maintain theattachment 105 at a position corresponding to historical value 284 of the grade profile 262 (such as cross slope and the mainfall) of theattachment 105 as thework machine 100 propels about a worksite. Mainfall may be the slope in the direction the work machine propels. In other embodiments, thesecond control signal 340 may be determined a number of ways aside from a historical value 284. The historical value 284 of the grade profile 262 comprises one of a snapshot in a current, an immediate past, a past point in time or alternatively a past period of time. In one embodiment, the second control signal 260 may be based on a filtered value, or a Kalman filter, or other sensor fusions. For example, in another embodiment the second control signal 260 may be based on an algorithm that tracks the slopes of the laser signal 235 (i.e. the laser plane) and the motion of thework machine 100, and then uses thefirst sensor 205 and the second sensor 210 (e.g. the IMUS) to predict the motion of the work machine relative to a tacked laser plane when thelaser signal 235 is missing. Alternatively, thesecond control signal 340 may be based on one of the first sensor signal and the second sensor signal and the kinematics between the frame and the attachment to estimate and control the implement height deviation from the historical values of the laser plane through, for example, a Kalman filter. - In this particular embodiment, the laser receiver 215 comprises of a
first receiver 275 and asecond receiver 280, wherein each receiver is located on afirst laser mast 115 and asecond laser mast 115, respectively. Thelaser masts 115 extend upwardly from a location fixed relative to theframe 110. Thefirst receiver 275 and thesecond receiver 280 create afirst height signal 240 a and asecond height signal 240 b, respectively. Thefirst height signal 240 a and thesecond height signal 240 b enabling thecontroller 10 to calculate one or more of the attributes of a grade profile 262 (such as cross slope and the mainfall) of theattachment 105. If either of thefirst height signal 240 a and thesecond height signal 240 b is disrupted, thecontroller 10 will generate thesecond control signal 340 based on the first sensor signal 220, the second sensor signal 225, and the remaining height signal. The height signal (240 a, 240 b) may possibly automatically control the height of thelaser receiver 280 to correspond to the height of a laser signal as thework machine 100 propels. - The historical value 284 may be derived from a predetermined period of time 285. The
processor 30 will record output from thefirst sensor 205 and the second sensor 210 (e.g. cross slope and mainfall) by deriving a sequence of averages of successive given numbers over a duration of time, and thereby evening out short-term fluctuations and clarifying grade profile 262 trends (such as cross slope and mainfall for example). Alternatively, the historical value 284 may be derived from a predetermined tolerance band 286 and thereby ignoring any outliers. In another embodiment, the historical value 284 may be derived from a predetermined number of passes 287 the work machine makes when grading asurface 135. For example, a final pass over a surface may require a higher sampling rate than an initial pass. - The historical value 284 may be derived from a sampling rate dependent on either a worksite condition 287 or the job function 289. For example, an architectural grading may require large changes in the contours of a land area for housing development. Whereas landscaping or turf development may require setting a slope for to create a desired drainage flow using rough grading. Finish grading, such as putting the final touches on a surface by removing large chunks of soil, rocks, or debris, may require greater accuracy and therefore a larger sampling rate. These are few examples of multiple applications when acquiring a grade profile 262 running average using the
first sensor 205 and thesecond sensor 210 in a grading operation. - The
controller 10 may further be configured to suspend theauto control mode 438 of maintaining theattachment 105 at a position after a period of time when thesecond control signal 340 is operating the one ormore actuators 197. If the laser receiver 215 continues to fail, by damage for example, or alternatively if thelaser beacon 237 discontinues operation wherein a laser signal is no longer transmitted over an extended period of time,auto control mode 438 may be suspended. Alternatively, thecontroller 10 may notify the operator that performance has degraded and allowing for the operator to decide whether or not to interrupt grade control. -
FIG. 3 discloses a flowchart of amethod 300 of automatically controlling a position of anattachment 105 on awork machine 100 during a grading operation of asurface 135 where theattachment 105 is movably coupled to theframe 110 via aboom assembly 170. The method comprises the following steps. Instep 305, the method includes establishing a target grade to establish a desired grade of the surface. Next instep 310, themethod 300 requires identifying a position of theattachment 105 with respect to either theframe 110, thesurface 135, and thelaser signal 235. Subsequently, instep 315, themethod 300 includes receiving a first sensor signal 220 from afirst sensor 205 wherein the first sensor signal 220 is indicative of an angle of theframe 110 relative to the direction of gravity. Then, instep 320, themethod 300 comprises receiving a second sensor signal 225 from asecond sensor 210 indicative of an angle of the ground-engagingattachment 105 relative to one of theframe 110 and the direction of gravity. Next instep 325, alaser signal 235 from alaser beacon 237 is received. Instep 330, themethod 300 includes generating a height signal 240 based on thelaser signal 235, wherein the height signal 240 is indicative of a position of one of theattachment 105 and theframe 110 relative to the laser signal 220. Then instep 335, themethod 300 includes generating a first control signal 255 based on the height signal 240 wherein the first control signal 255 causes one ormore actuators 197 coupling the attachment to the work machine to maintain theattachment 105 at a position corresponding to thetarget grade 305 as thework machine 100 propels about the worksite 245. Finally, instep 340, the method includes generating asecond control signal 340 based on one of the first sensor signal 220 and the second sensor signal 225, in the absence of the height signal 240, wherein thesecond control signal 340 operates the one ormore actuators 197 to maintain theattachment 105 at a position corresponding to historical value 284 of a grade profile (e.g. cross slope and mainfall) as thework machine 100 propels about a worksite 245. - Now turning to
FIG. 4 a logic flow diagrams illustrating one embodiment of the adaptive control system for grade control 200 is shown. The system 200 includes a series of processing instructions or steps that are depicted in flow diagram form. The process begins at 410 wherein the grade profile 262 of the attachment 105 (e.g. cross slope and mainfall) is calculated. Individual inputs forstep 410 include the first laser receiver 215 (also referred to as LR1) receiving afirst laser signal 235 from a laser beacon instep 402, the second laser receiver 215 (also referred to as LR2) receiving asecond laser signal 235 from thelaser beacon 237 instep 404, a first sensor signal 220 from afirst sensor 205 instep 406, and a second sensor signal 225 from asecond sensor 210 instep 408. Atstep 410, during system setup, a user, operator, worksite plan, or other individual inputs of information associated with the grade control system 200, a target grade is entered. Step 410 also includes calculating historical value 284 of one or more of the grade profile 262 based on time 285, tolerance 286, number of passes 287, worksite condition 288, or job function 289. The information with respect to the grade profile 262 from thefirst sensor 205 and thesecond sensor 210 is stored inmemory 20. Instep 418, if thefirst laser receiver 275 is generating aheight signal 240 a, the logic sets the value to true instep 422. However, if there is an obstruction or equipment failure leading to a lack of height signal generation, the logic sets the value to false instep 424. Similarly, instep 412, if the second laser receiver 280 (also referred to as LR2) is generating aheight signal 240 b, the logic sets the value to true in 416. However, if there is a lack of height signal generation, the logic sets the value to false instep 414. Instep 424, the logic determines whether thefirst laser receiver 275 and thesecond laser receiver 280 have a value of true. If they are both true, the logic moves to step 426, generating a first control signal 255 for the hydraulic system based on both height signals 240 for grade control. However, if either thefirst laser receiver 275 or thesecond laser receiver 280 has a value of false, a time counter begins instep 428. If thelaser signal 235 is disrupted greater than a specified timeframe instep 432 and 436 (e.g. 60 seconds), either auto control mode is suspended or the operator is notified that performance is degraded 438. If thelaser signal 235 is disrupted less than the specified timeframe instep 432 and 436 (e.g. 60 seconds), an alternate control signal is generated. Instep 434, a second control signal 260 is generated if both the first 275 andsecond laser receiver 280 have a value of false wherein the second control signal 260 is based on the first sensor signal 220 and the second sensor signal 225. However, instep 440, if only one laser receiver has a false value and the other has a true value, athird control signal 440 is generated based on the laser receiver set to true and the alternate sensor signal. - The adaptive control system and method for grade control disclosed herein has certain advantages. Notably, the system can maintain accuracy and continuity of the grading operation, and thereby eliminating inefficiencies in the process. Furthermore, the system enables a work machine to run automated by eliminating blips in equipment function, without necessarily requiring an operator to be present in the work machine.
- As used herein, “e.g.” is utilized to non-exhaustively list examples, and carries the same meaning as alternative illustrative phrases such as “including,” “including, but not limited to,” and “including without limitation.” As used herein, unless otherwise limited or modified, lists with elements that are separated by conjunctive terms (e.g., “and”) and that are also preceded by the phrase “one or more of” “at least one of,” “at least,” or a like phrase, indicate configurations or arrangements that potentially include individual elements of the list, or any combination thereof. For example, “at least one of A, B, and C” and “one or more of A, B, and C” each indicate the possibility of only A, only B, only C, or any combination of two or more of A, B, and C (A and B; A and C; B and C; or A, B, and C). As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Further, “comprises,” “includes,” and like phrases are intended to specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof.
Claims (20)
1. An adaptive control system for a work machine for automatically controlling an attachment position during a grading operation of a surface, the adaptive control system comprising:
a frame;
an attachment movably coupled to the frame via a boom assembly;
a first sensor configured to generate a first sensor signal indicative of an angle of the frame relative to the direction of gravity;
a second sensor configured to generate a second sensor signal indicative of an angle of the ground-engaging attachment relative to one of the frame and the direction of gravity;
a laser receiver configured to receive a laser signal from a laser beacon, the laser receiver generating a height signal based on the laser signal, the height signal indicative of a position of one of the attachment and the frame relative to the laser signal; and
a controller having a non-transitory computer readable medium with a program instruction to grade the surface, the program instructions when executed causing a processor of the controller:
establish a target grade based on a desired grade of the surface;
identify a position of the attachment with respect to one of the frame, the surface, and the laser signal;
receive the first sensor signal from the first sensor;
receive the second sensor signal from the second sensor;
receive the laser signal from the laser beacon;
generate a first control signal based on the height signal, the first control signal causing one or more actuators coupling the attachment to the work machine to maintain the attachment at a position corresponding to the target grade as the work machine propels; and
generate a second control signal based on one of the first sensor signal and the second sensor signal in the absence of the height signal, the second control signal causing one or more actuators coupling the attachment to the work machine to maintain the attachment at a position corresponding to a historical value of a grade profile of the attachment as the work machine propels.
2. The adaptive control system of claim 1 , wherein the laser receiver comprises of a first receiver and a second receiver, wherein each receiver is located on a first laser mast and a second laser mast, respectively, the laser masts extending upwardly from a location fixed relative to the frame.
3. The adaptive control system of claim 2 , wherein the first receiver and the second receiver create a first height signal and a second height signal, respectively, the first height signal and the second height signal enabling the controller to calculate a grade profile of the attachment.
4. The adaptive control system of claim 3 , wherein in the absence of one of the first height signal and the second height signal, the controller generates a third control signal based on the first sensor signal, the second sensor signal, and the remaining height signal.
5. The adaptive control system of claim 1 , wherein the historical value is derived from a predetermined period of time.
6. The adaptive control system of claim 1 , wherein the historical value is derived from one of a predetermined tolerance band and a predetermined number of passes.
7. The adaptive control system of claim 1 , wherein the historical value is based on a sampling rate dependent on one of a worksite condition and a job function.
8. The adaptive control system of claim 1 , wherein the processor is further configured to create a performance degradation alert signal for the grading operation after a predetermined period of time of the second control signal operating the one or more actuators.
9. The adaptive control system of claim 1 , wherein the processor is further configured to suspend an auto control mode of maintaining the attachment for the grading operation after a predetermined time of the second control signal operating the one or more actuators.
10. The adaptive control system claim 1 , wherein the height signal automatically controls the height of the laser receiver to correspond to the height of the laser signal as the work machine propels.
11. The method of automatically controlling a position of an attachment on a work machine during a grading operation of a surface, the attachment movably coupled to the frame via a boom assembly, the method comprising:
establishing a target grade to establish a desired grade of the surface;
identifying a position of the attachment with respect to one of the frame, the surface, and the laser signal;
receiving a first sensor signal from a first sensor, the first sensor signal indicative of an angle of the frame relative to the direction of gravity;
receiving a second sensor signal from a second sensor, the second sensor signal indicative of an angle of the ground-engaging attachment relative to one the frame and the direction of gravity;
receiving a laser signal from a laser beacon;
generating a height signal based on the laser signal received, the height signal indicative of a position of one of the attachment and the frame relative to the laser signal;
generating a first control signal based on the height signal, first the control signal causing one or more actuators coupling the attachment to the work machine to maintain the attachment at a position corresponding to the target grade as the work machine propels; and
generating a second control signal based on one of the first sensor signal and the second sensor signal in the absence of the height signal, the second control signal causing one or more actuators coupling the attachment to the work machine to maintain the attachment at a position corresponding to historical value of a grade profile as the work machine propels.
12. The method of claim 11 , wherein the laser signal is received on a first receiver and a second receiver located on a first laser mast and a second laser mast, respectively, the laser masts extending upwardly from a location fixed relative to the frame.
13. The method of claim 12 , wherein the first receiver and the second receiver create a first height signal and a second height signal, respectively, the first height signal and the second height signal enabling the controller to calculate one of a grade profile of the attachment.
14. The method of claim 13 , wherein in the absence of absence of one of the first height signal and the second height signal, the method includes generating a third control signal based on the first sensor signal, the second sensor signal, and the remaining height signal.
15. The method of claim 11 , wherein the historical value is derived from a predetermined period of time.
16. The method of claim 11 , wherein the historical value is derived from one of a predetermined tolerance band and a predetermined number of passes.
17. The method of claim 11 , wherein the historical value is based on a sampling rate dependent on one of a worksite condition and a job function.
18. The method of claim 11 , wherein the method further comprises creating a performance degradation alert signal for the grading operation after a predetermined period of time of the second control signal operating the one or more actuators.
19. The method of claim 11 , wherein the method further comprises suspending auto control mode of maintaining the attachment at a position after a predetermined time of the second control signal operating the one or more actuators.
20. The method of claim 11 , wherein the height signal automatically controls the height of the laser receiver to correspond to the height of a laser signal as the work machine propels.
Priority Applications (3)
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US17/804,221 US20230383497A1 (en) | 2022-05-26 | 2022-05-26 | Work machine with an adaptive control system and method for grade control |
DE102023108154.3A DE102023108154A1 (en) | 2022-05-26 | 2023-03-30 | WORK MACHINE WITH AN ADAPTIVE CONTROL SYSTEM AND METHOD FOR GRADING CONTROL |
AU2023202519A AU2023202519A1 (en) | 2022-05-26 | 2023-04-26 | A work machine with an adaptive control system and method for grade control |
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US17/804,221 US20230383497A1 (en) | 2022-05-26 | 2022-05-26 | Work machine with an adaptive control system and method for grade control |
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AU (1) | AU2023202519A1 (en) |
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