Patent Grant
8660738
This disclosure relates generally to systems and methods for monitoring the performance of equipments and equipment operators.
Off-highway trucks, wheel loaders, excavators and other types of equipment are often called upon to perform repetitive segments or repetitive applications that include a sequence of segments. Methods for monitoring the performance such equipment and equipment operator performance currently exist and are important as management is provided with information about the equipment productivity, operator productivity, application efficiency and energy consumption.
Some of these monitoring methods utilize an approach in which operating parameters are monitored. For example, U.S. Pat. No. 5,955,706 measures lift cylinder pressure, lift cylinder displacement, tilt cylinder displacement, the direction of travel and other parameters to determine which segments of an application or work cycle the machine is undertaking. Individual segments and the overall application or cycle are timed. Similar monitoring is disclosed in U.S. Pat. No. 5,105,895 where sensed data is used to determine the application being performed and to monitor productivity.
It may also be desirable or necessary to monitor the performance of equipment operators in addition to or instead of the equipment itself. The need to monitor operator performance may be for managerial purposes to ensure that operators are complying with a minimum standard of performance and to help identify areas of potential operator improvement. Monitoring operator performance may also be desired by operators to provide the operator with an indication of their own performance in comparison with other operators and to demonstrate their level of competence to management.
One field in which performance monitoring is particularly effective is the operation of wheel loaders and excavators. Wheel loaders and excavators are expensive equipment. To ensure that the value of a wheel loader or excavator is being fully realized, it is important that an operator is operating the equipment efficiently. There are, however, many factors that need to be measured and considered to enable fair and useful comparisons to be made between different operators, between different pieces of equipment, between present and previous performances and between different operating conditions.
It is therefore desirable to provide a system and/or method capable of fairly evaluating an operator and a piece of equipment. Furthermore, it is desirable that performance-monitoring information is displayed in the cab and promptly made available to management and equipment operators alike of current performance-monitoring information.
A system for evaluating performances of a machine and an operator of the machine is disclosed. The system may include a controller linked to a plurality of sensors for sensing a plurality of operating parameters of the machine. The controller may have a memory programmed with an algorithm for resolving a plurality of segments the machine is sequentially performing from the sensed operating parameters to provide a sequence of resolved segments. The memory of the controller may be programmed with an algorithm for resolving what application the machine is performing based on the sequence of resolved segments to provide at least one resolved application. The memory of the controller may also be programmed to apply at least one metric to the resolved application to provide at least one applied application metric for evaluating the performance of the machine and operator using the applied application metric.
In another system for evaluating the performances of a piece of equipment and an operator of the equipment, the equipment includes an engine, a transmission, a work implement, a lift cylinder, and a tilt cylinder connected to the work implement, and an implement pump. The system for evaluating includes a plurality of sensors for sensing a plurality of operating parameters. The sensors are linked to at least one control module. The at least one control module may be programmed to measure fuel consumption rate, payload weight, transmission gear, transmission output speed, lift angle, tilt angle, lift command, tilt command, and implement pump discharge pressure. The at least one control module may also include a memory programmed to resolve which plurality of segments the equipment and operator are sequentially performing from the sensed operating parameters to provide a sequence of resolved segments. The memory of the at least one control module may also be programmed to apply at least one metric to the sequence of resolved segments to provide at least one applied segment metric. The memory of the at least one control module may also be programmed to resolve what application the equipment is performing based upon the sequence of resolved segments to provide at least one resolved application. The memory of the at least one control module may also be programmed to apply at least one metric to the resolved application to provide at least one applied application metric. The system may also include a display linked to the at least one control module for displaying the at least one applied segment metric and the at least one applied application metric.
Methods of evaluating the performances of a piece of equipment and a piece of equipment operator are also disclosed. The disclosed method includes sensing a plurality of operating parameters of the equipment and resolving which plurality of segments that the equipment is sequentially performing based on the sensed operating parameters to provide a sequence of resolved segments. The method further includes resolving what application the equipment is performing based on the sequence of resolved segments to provide at least one resolved application. The method further includes applying at least one metric to the resolved application to provide at least one applied application metric. The method also includes evaluating the performance of the equipment and operator using the applied application metric.
Another disclosed method for evaluating performances of a piece of equipment and a piece of equipment operator includes sensing a plurality of operating parameters of the equipment and resolving which plurality of segments that the equipment and operator are sequentially performing based on the sensed operating parameters to provide a sequence of resolved segments. At least one metric is applied to at least one segment of the sequence of resolved segments to provide at least one applied segment metric. The method further includes resolving what application the equipment is performing based on the sequence of resolved segments to provide at least one resolved application and applying at least one metric to the resolved application to provide at least one applied application metric. The method also includes evaluating the performance of the equipment and operator using at least one of the applied segment metric and the applied application metric.
In any one or more of the disclosed methods or systems, the at least one operating parameter may be selected from the group consisting of engine speed, hydraulic pressure of lift cylinder, hydraulic pressure of tilt cylinder, lift lever position, tilt lever position, lift cylinder extension, tilt cylinder extension, transmission gear, transmission output speed, transmission input speed, implement pump discharge pressure, fuel consumption rate and payload weight.
In any one or more of the systems or methods described above, each segment may be selected from the group consisting of dig, travel loaded, dump, travel empty, swing loaded, swing empty, scrape, scrape dump, blade load, carry material, stationary weigh, spread material, return, equipment idle, grade, general travel, stationary loaded high idle, stationary loaded low idle, stationary empty high idle and stationary empty low idle.
In any of the methods or systems described above, the application may be selected from the group consisting of idle time, roading, loading, pile cleanup, load and carry, road maintenance, excavate, trenching, stockpiling and slot dozing.
In any of the methods or systems described above, at least one segment metric is applied to the resolved segments to provide at least one of applied segment metric.
In any one or more of the methods or systems described above, the segment metric may be selected from the group consisting of duration, fuel consumption, distance, payload, GPS coordinates, transmission gear, operating efficiency, average engine speed, average engine coolant temperature, average hydraulic pressure of lift cylinder, average hydraulic pressure of tilt cylinder, hydraulic pump pressure, hydraulic circuit pressure, hydraulic oil temperature and energy consumption.
In any one or more of the methods or systems described above, the application metric may be selected from the group consisting of duration, fuel consumption, distance, payload, GPS coordinates, transmission gear, operating efficiency, average engine speed, average engine coolant temperature, average hydraulic pressure of lift cylinder, average hydraulic pressure of tilt cylinder, hydraulic pump pressure, hydraulic circuit pressure, hydraulic oil temperature and energy consumption.
In any one or more of the methods or systems described above, the applied segment metric and/or the applied application metric may be displayed on a visual display that can be seen by the operator. Such a visual display may be mounted in the cab of the equipment.
In any one or more of the methods or systems described above, the number of applications performed in a trip may be calculated. A trip may be defined as a shift, such as a work shift, a day or other predetermined time periods.
In any one or more of the methods or systems described above, at least one metric may be applied to the calculated number of applications in the trip to provide at least one applied trip metric. The at least one applied trip metric may be selected from the group consisting of production mass per unit time, fuel consumption in unit volume of fuel per unit time, efficiency in mass of material moved per unit volume of fuel, average time per application, average number of applications per trip, total payload per trip, total fuel consumed per trip and total time per trip.
In any one or more methods or systems described above, the at least one applied trip metric may be displayed on the visual display that can be seen by the operator.
This disclosure enables equipment operators to monitor application (cycle) time and other performance metrics (productivity, efficiency, and fuel consumption) per application onboard a piece of equipment without manual interface. This disclosure also provides for the transmission to management of data including machine and operator productivity, efficiency, and energy (or fuel) consumption. The data, or the analysis of the data, allow management to make better decisions on operator coaching, machine placement, maintenance scheduling. The same data can be given to dealers and manufacturer to track, manage and plan improvements. In addition to wheel loaders and excavators, this disclosure is applicable to any piece of equipment with the linkage, the extension or attraction of which can be sensed, or any equipment that performs different, but distinct applications (operations).
In this disclosure, the application may be identified after it has been segmented or broken down into specific segments. Each segment of an application may be timed and performance metrics may be recorded for each segment as well as the application as a whole (e.g., productivity, fuel consumption, efficiency etc.). For example, a wheel loader operator may be loading a truck. Truck loading would be the application. The disclosed algorithm would identify individual segments, such as dig, travel loaded, dump, and travel empty segments when identifying truck loading as the application. For each of these segments, performance metrics would be recorded. This combination of segments forms a truck loading application, causing the algorithm to record a truck loading application with appropriate performance metrics.
In
The equipment 21 includes a transmission 36 and one or more transmission sensors shown at 37. The one or more transmission sensors 37 may generate signals indicative of transmission output speed, transmission input speed, transmission gear, direction of travel etc. for generating signals. The lift sensor 34 may also send data to the controller 35 for generating a lift cylinder displacement. The equipment 21 includes an engine 41 and one or more engine sensors 42 that may generate data that is transmitted to the controller 35 and which is used to generate operating parameters such as engine speed, fuel rate, etc.
The equipment 21 may also include a tilt lever 48 and lift lever 49. The tilt lever 48 may include one or more tilt lever sensors 51 and the lift lever 49 may include one or more lift lever sensors 52. The sensors 51, 52 may be linked to the controller 35 for purposes of generating a tilt command signal or a lift command signal. The equipment may also be equipped with a GPS system 55 and one or more hydraulic pumps, one of which is shown at 56 in
A hybrid schematic illustration and flow chart of the equipment 21, the disclosed system 20 and disclosed method is provided in
After one or more segments or a sequence of segments is resolved at 62, the controller 35 may be programmed to resolve which application the equipment 21 is undertaking based on the resolved segment or resolved sequence of segments at step 63. For example, based upon a sequence of segments, the controller 35 may determine that the equipment 21 is undertaking a loading application, a load and carry application, a pile cleanup application, a roading application, or some other application typically carried out by the equipment 21. At step 64, one or more application metrics may be applied to the resolved application for generating one or more applied application metrics such as application duration, application fuel use, distance traveled, payload, production rate, efficiency, idle time, etc. The one or more applied application metrics and one or more applied segment metrics may be displayed on a visual display 65 as illustrated in
Definitions of Applications, Segments and Metrics
A list of possible applications, segments and metrics and their definitions is presented below:
A controller 35 may be programmed with an information management system, such as a vital information management system (VIMS), which collects and transmits equipment data and turns it into valuable information used to track productivity, equipment performance, surface scheduling, trends, diagnostics, and equipment condition monitoring. The controller 35 is preferably located on board the equipment 21. A third generation of the VIMS system (VIMS3G) (I believe the 3G stands for the cellular communication protocol, not the 3rd generation of the VIMS system) is also now available from the assignee, Caterpillar of Peoria Ill., USA. In addition to providing production and performance information, the VIMS may also provide detection of an impeding or abnormal condition in one or more of the systems of the equipment 21 and alerting of the operator to take an appropriate action in response to the impeding or abnormal condition.
The GSM communication system may also include an additional application provided by Caterpillar under the VISIONLINK™ trademark which is a communications interface. The VISIONLINK application provides the capability to communicate on a cellular network (GSM), which is advantageous due to its wide band width and therefore the ability to accommodate large quantities of data. Existing satellite-based hardware can be upgraded to accommodate such an application.
Finally,
Accordingly, various systems and methods for monitoring the performance of a piece of equipment and the equipment operator of that equipment are disclosed. Sensors are provided for generating various signals that are sent to a controller 35. The various sensors may include, but are not limited to engine speed, gear, transmission output speed and direction, torque converter output speed, lift lever command, tilt lever command, lift position, tilt position, implement pump discharge pressure, fuel consumption rate and payload. The disclosed systems use equipment sensor signals and define segmentation rules to calculate cycle counts, durations, distances, energy usage and various performance indexes to inform and/or coach the operator and to inform the manager/owner of the equipment. When combined with a payload calculation system, cycle payloads can be combined with performance metrics to calculate production information such as payload/hour and payload/fuel.
The controller 35 includes a memory 61 that may be programmed with software that resolves which segment is being performed based upon the sensor input signals. The segments include, but are not limited to, travel empty (travel before dig), dig (begins with a bucket parallel and close to the ground and ends with the bucket in a carry position), travel loaded (travel after dig), stationary weigh (equipment not moving, lifting or lowering implement to determine payload), dump (dump material as bucket moves from carry position to dump position), scrape (pick up material for pile dressing with bucket parallel and close to the ground), scrape dump (dump scraped material from a partially racked bucket position), idle and miscellaneous stationary positions. From the resolved segment or segments, a sequence of resolved segments can be defined and from a sequence of resolved segments, an application that the equipment is undertaking can be determined. The various applications include, but are not limited to, loading (segments include travel empty, dig, stationary weigh, travel loaded, dump), load and carry (segments include travel empty, dig, stationary weigh, travel loaded, dump), stock piling (segments include scrape, scrape dump, travel empty), roading (segment includes travel empty), equipment idle time and miscellaneous time (non-recognized cycles or partial cycles). From the resolved segments and applications, equipment utilization information is calculated for display to the operator on the visual display 65 or stored in the memory 61 for off-site processing. Information or applied metrics include, but are not limited to:
A system is provided for evaluating the performance of a piece of equipment, wherein the equipment performs one or more applications, with each application including at least one segment or task. The system includes a controller in communication with a plurality of sensors that can detect various aspects of the operation of the equipment. For example, the controller may be in communication with any one or more of a lift sensor, tilt sensor, transmission sensor, engine sensor, tilt lever sensor, lift lever sensor, hydraulic pump, etc. From the data transmitted to the controller by the sensor or sensors, the controller can resolve which segment the piece of equipment is undertaking and, from a plurality of resolved segments, which application the piece of equipment is currently undertaking. The controller may then apply various metrics to the data for purposes of evaluating or monitoring the piece of equipment and the equipment operator.
One disclosed method for evaluating the performance of a piece of equipment and an operator of a piece of equipment include sensing a plurality of operating parameters of the equipment, resolving a plurality of segments the equipment and operator are sequentially performing from the sensed operating parameters to provide a sequence of resolved segments, applying at least one metric to at least one segment of the sequence of resolved segments to provide at least one applied segment metric, resolving what application the equipment is performing based upon the sequence of resolved segments to provide at least one resolved application, applying at least one metric to the resolved application to provide at least one applied application metric and evaluating the performance of the equipment and operator using at least one of the applied segment metric and applied application metric.
Typical industrial applications include use of a medium wheel loader in a quarry or sand and gravel pit that may involve loading trucks to within an accuracy of 0.22 tonnes (500 pounds) or 0.45 tonnes (1,000 pounds). Such an operation may include loading of railcars, river barges, or a hopper a short distance away. Such an operation may also include feeding hoppers for aggregate production, stock piling or conducting truck/loader path maintenance. In an asphalt plant, such a medium wheel loader may be used to keep hoppers filled with aggregates, stock pile incoming aggregates and recycled materials, and yard maintenance or cleanup. In a concrete ready-mix plant, loader jobs include, but are not limited to, keeping hoppers filled with aggregate, stock piling incoming aggregates, concrete truck carry back sludge disposal and yard maintenance and cleanup.
In addition to the visual display 65 screen formats illustrated in
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