MACHINE CONTROL SYSTEM AND METHOD

Abstract

A global navigation satellite system (GNSS) based control system is provided for positioning a working component relative to a work surface, such as an agricultural spray boom over a crop field. Inertial measurement unit (IMU) sensors, such as accelerometers and gyroscopes, are mounted on the working component and provide positioning signals to a control processor. A method of positioning a working component relative to a work surface using GNSS-based positioning signals is also disclosed. Further disclosed is a work order management system and method, which can be configured for controlling the operation of multiple vehicles, such as agricultural sprayers each equipped with GNSS-based spray boom height control subsystems. The sprayers can be remotely located from each other on multiple crop fields, and can utilize GNSS-based, field-specific terrain models for controlling their spraying operations.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to automated machine control, which can be configured for work order management involving multiple agricultural vehicles and crop fields, and in particular to a global navigation satellite system (GNSS) based agricultural spray boom height control system and method.

2. Description of the Related Art

Mobile equipment and machinery, including vehicles, agricultural equipment, open-pit mining machines and crop duster aircraft, are commonly guided and operationally controlled using global navigation satellite system (GNSS) components. Currently-available satellite positioning systems (SATPS) provide parallel and contour swathing for precision farming. For example, equipment can be guided or automatically steered along adjacent parallel path swaths, which can be offset from each other by approximately the vehicle width in a parallel path mode of operation.

Various GNSS-based navigation systems have been installed in ground-based vehicles. Systems using Doppler radar guidance systems can encounter positioning errors with the radar and latency. Similarly, gyroscopes and accelerometers (collectively inertial measurement units (IMUs) provide heading, roll and pitch measurements (e.g., XYZ headings). However, IMUs tend to encounter drift and bias errors requiring external attitude measurements for gyroscope initialization and drift compensation. Gyroscopes have good short-term characteristics but undesirable long-term characteristics, especially lower-cost gyroscopes, such as those based on vibrating resonators.

Similarly, inertial systems employing gyroscopes and accelerometers have good short-term characteristics but also suffer from drift. Existing GNSS position computations may include lag times, which may be especially troublesome when, for example, GNSS velocity is used to derive vehicle heading. Many existing GNSS systems do not provide highly accurate heading information at slower vehicle speeds. Therefore, what is needed is a low cost sensor system to facilitate vehicle swath navigation that makes use of the desirable behaviors of both GNSS and inertial units while eliminating or reducing non-desirable behavior. Specifically, what is needed is a means to employ low-cost gyroscopes (e.g., micro electromechanical (MEM) gyroscopes) which tend to provide good short-term, low-noise, high-accuracy positioning while minimizing inherent long-term drift.

Providing multiple antennas on a vehicle can provide additional benefits by determining an attitude of the vehicle from the GNSS ranging signals received by its antennas, which are constrained on the vehicle at a predetermined spacing. For example, high dynamic roll compensation signals can be output directly to the vehicle steering using GNSS-derived attitude information. Components such as gyroscopes and accelerometers can be eliminated using such techniques. Real-time kinematic (RTK) navigation can be accomplished using relatively economical single frequency L1—only receivers with inputs from at least two antennas mounted in fixed relation on a rover vehicle. Still further, moving baselines can be provided for positioning solutions involving tractors and implements and multi-vehicle GNSS control can be provided.

Providing additional antennas in combination with standard SATPS and GNSS guidance, as mentioned above, along with optional gyroscopes, can provide an effective method to increase GNSS positioning precision and accuracy. However, accuracy and precision can only improve the efficiency of working vehicles, such as those in the agricultural field, to a limited extent. Although such systems are able to track and guide vehicles in three dimensions, including along ridges and sloped-regions, errors may appear in other aspects of a working vehicle. For example, in an agricultural field-working situation where a tractor is towing an implement, the implement may slide on a sloped-region, or the tractor may list to one side or another when entering softer soil or rocky areas. This can happen repeatedly when a vehicle is guided around the same field, regardless of the precision of the guidance system in pre-planning a path. Thus, a system that can detect such changes in uniformity of a field as the vehicle traverses a path, and can remember those changes, can predict and re-route a more accurate and more economical path than a guidance system alone.

Conventional agricultural spraying operations are carried out over an entire field, everywhere the crop is planted. In contrast, environmental spraying allows the spraying of certain materials which require restrictions in the area of deposition due to potential toxicity or strength. The restrictions can include the distance from waterways and slope of the ground which can affect run-off and concentrations of deposits. In spray equipment with booms, maintaining uniform boom height over field surfaces during product application is important for uniform application rates and optimum product drift management relative to the targets, e.g., field crops. These systems are limited in performance due to their ability to look ahead and react with a spray vehicle traveling at a high rate of speed. In addition, these methods encounter issues when there are rapid changes in terrain or skips in crop canopy. The present invention addresses both issues.

GNSS-based precision application of agricultural inputs, such as pesticides, fertilizers and seeds, are commonly performed with large fleets of vehicles dispatched from common or networked home-base locations. Communication of mission planning information to all working vehicles, in real time, is paramount to efficiency. One piece of such information, which is a key to the present invention, is the terrain model, which can be created with specialized software using previously-logged field data containing highly precise positioning information from real-time kinematic (RTK) GNSS receivers. The logged data can be uploaded to the processing center from the logging vehicle through any data connection, although a wireless/remote connection is most desired for efficiency. Once processed, the terrain models can be dispatched from the home-base or processing center location to any vehicle via wireless data connection. The data is thus available to operators preparing to work fields using the boom height control system of the present invention. Using wireless data connectivity, the Internet (i.e., via the “Cloud”) enables efficient use of a boom height invention via the seamless transfer of the terrain model, which is a key component of the system.

Work order management functions for coordinating multiple machines at multiple remote locations can be accommodated with the present invention.

Previous spray boom height control systems include sonic sensors for measuring spray boom heights over ground surfaces and crop canopies.

Heretofore there has not been available a system and method with the advantages and features of the present invention.

SUMMARY OF THE INVENTION

In the practice of the present invention, position sensors (such as GNSS and IMU) are used to accurately locate the implement (such as a spray boom) with reference to the ground, standing crop, or other field features. Real time compute engine processes control algorithms to compare sensor data with spatial data logged from a previous operation, or terrain model, to make control decisions which maintain desired implement height. Work order management systems and methods can be combined with the machine control functions of the present invention to further automate operations, including agricultural operations involving multiple machines operating at multiple locations and sharing data with each other and with centralized data facilities.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings constitute a part of this specification and include exemplary embodiments of the present invention illustrating various objects and features thereof.

FIG. 1 is a schematic diagram of a boom height control system embodying an aspect of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

I. Introduction and Environment

As required, detailed aspects of the present invention are disclosed herein, however, it is to be understood that the disclosed aspects are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art how to variously employ the present invention in virtually any appropriately detailed structure.

Certain terminology will be used in the following description for convenience in reference only and will not be limiting. For example, up, down, front, back, right and left refer to the invention as orientated in the view being referred to. The words, “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the aspect being described and designated parts thereof. Forwardly and rearwardly are generally in reference to the direction of travel, if appropriate. Said terminology will include the words specifically mentioned, derivatives thereof and words of similar meaning.

II. Preferred Embodiment

FIG. 1 is a schematic diagram of a boom height control system 2. Without limitation on the generality of useful applications of the present invention, the system 2 is shown for controlling the height of a spray boom 20, which can be used for agricultural applications, such as spraying fertilizer, herbicides, pesticides, water, etc. The control system 2 includes a guidance system 4, which can be global navigation satellite system (GNSS) based. A real-time control compute engine 6 is connected to the guidance system 4 and can be programmed with specific control instructions and applications, including variable-rate (VR), selective control, guidance, auto-steering, etc. A valve drive 8 can be connected to the compute engine 6 for connection to a steering system of a vehicle, such as a tractor or a self-propelled equipment piece.

The guidance system is connected to a job set up and graphical user interface (GUI) component 10, which can include suitable display monitor components. A field template file 12 is provided for specific fields and includes such information as GNSS-defined field coordinates, material prescription information, environmental conditions and equipment routing directions. Geodesic (e.g., geographic) information system (GIS) and cloud (e.g., Internet) 14 data sources and connectivity are provided for communicating bi-directionally with the other components of the system 2.

Boom inertial measurement units 16 are connected to the control compute engine 6, and can include such devices as accelerometers and gyroscopes for measuring inertia and positioning information in three axes (X, Y, Z). The boom 20 can include a GNSS receiver with an antenna 18, or can be directly controlled via the implement motive component, such as a tractor. The boom 20 includes sections 22, 24, 26, 28, 30, each equipped with its own inertial measurement unit (IMU) 16. The boom sections can be articulated for conforming to field conditions.

The system 2 can utilize a terrain model of the field, including field boundaries, topography, soil conditions, crop data and other pertinent information. Moreover, the terrain models can be generated in real-time as the equipment traverses the field, transmitted from the mobile equipment to a centralized server or base, and re-transmitted to the equipment for use in current field operations, which can be done based on work orders. Multiple mobile equipment pieces engaged in multiple different field locations can be controlled and coordinated.

III. Agricultural Spray Boom Height Control Method

Without limitation, the system 2 can be used for practicing a method of the present invention for controlling the height of an agricultural spray boom using the following steps:

• 1) Field is logged/mapped using highly accurate sensors (such as RTK GNSS) for measurement of field terrain elevations. This may be done as an independent step using an ATV or field truck, or data may be used/collected from another farming operation such as harvesting, which covers the same terrain.
• 2) Field log data may be stored and processed in an office/cloud GIS and data management toolset. The data element can be transferred from the field to the office and back using a remote data connection networking fleet vehicles with physical dispatch locations.
• 3) File is loaded in guidance system on target machine (sprayer, for example).
• 4) User selects the job file in the guidance system which includes the processed elevation data.
• 5) The user chooses/sets up boom control options to use the field log including desired height above the target.
• 6) As the system works across the field, sensor data is compared to elevation data and performs real-time control through a mechanical control system (typically electro-hydraulic or mechanical in nature).

IV. Alternative Embodiment Agricultural Spray Boom Height Control

The system 2 can also be used in conjunction with a work order management system for controlling multiple pieces of equipment (e.g., without limitation, agricultural vehicles equipped with spray booms 20). Work order status including location, equipment status and field conditions can be transmitted via the cloud 14 to a central location equipped with a computer for coordinating the operation of a fleet of agricultural vehicles. A variety of user interface devices, including vehicle-mounted computers, smart phones, hand-held devices, etc. can be utilized. Data can be transmitted to and from the vehicles in real-time. Alternatively, data can be stored for later retrieval and processing (e.g., on removable storage media such as USB thumb drives, CDs, DVDs, etc.). These can be periodically downloaded and data thereon transferred to a central control computer or system.

Such data can include, without limitation, field terrain models as described above. Other data can comprise, for example, work orders, crop data, agricultural input (e.g., fertilizers, herbicides, seeds, nutrients, etc.) and machine-specific performance and location information. The system is scalable for accommodating multiple fields and fleets of vehicles, which can be located in proximity to, or remote from, each other. By interconnecting the vehicles via the cloud, specific operations (e.g., spray boom heights, spray materials and field conditions), can be recorded for reporting, monitoring, evaluating, tracking and controlling operations.

It is to be understood that while certain embodiments and/or aspects of the invention have been shown and described, the invention is not limited thereto and encompasses various other embodiments and aspects.

Claims

1. A system for controlling the position of a working component relative to a work surface, which system includes: a global navigation satellite system (GNSS)-based positioning subsystem;said control system including a sensor associated with said working component and configured for providing output corresponding to a position of said working component relative to the work surface;a processor connected to said control subsystem;said processor including a memory device configured for storing work surface data based on output from said GNSS positioning subsystem and said sensor; andsaid control system is configured for positioning said working component relative to said work surface.

2. The control system according to claim 1 wherein said sensor includes an inertial measurement unit (IMU) mounted on said working component.

3. The control system according to claim 1, wherein said working component comprises an agricultural sprayer including a spray boom, said work surface comprises a crop field and said work surface data comprises a terrain model of said crop field.

4. The control system according claim 3 wherein said spray boom comprises multiple boom sections and said control system is configured for independently controlling the heights of said boom sections over said crop field.

5. The control system according to claim 1, which includes: a memory device connected to said processor and configured for storing working component positions relative to said work surface using said terrain model.

6. The control system according to claim 5, which includes: said processor being connected to a central control computer via the Internet.

7. The control system according to claim 4 wherein said control system is configured for synchronizing the operation of multiple equipment pieces on one or more crop fields.

8. The control system according to claim 4 wherein said control system is configured for monitoring, storing and reporting operation data for said equipment pieces.

9. The control system according to claim 8 wherein said equipment pieces comprise agricultural sprayers and said operation data includes quantities of material dispensed by said agricultural sprayers.

10. The control system according to claim 9 wherein said operation data includes the GNSS-defined locations of said material dispensed by said agricultural sprayer.

11. A control system for controlling the position of a working component of equipment relative to a work surface, which system includes: a global navigation satellite system (GNSS)-based positioning control subsystem;an inertial measurement unit (IMU) sensor mounted on said working component and connected to said control subsystem;one or more sensors associated with said working component and each configured for providing output comprising signal data corresponding to an operating or status condition;a first computer;a second computer associated with said equipment and connected to said control subsystem, said second computer including a display device;said first and second computers being wirelessly connected; andsaid first computer including a memory database configured for storing field data related to positioning parameters based on previous output from said GNSS, said IMU sensor, and said one or more sensors associated with said working component and configured for creating a terrain model.

12. The system according to claim 11, which includes: said first computer being configured to allow a user to access said stored field data;a first computer algorithm executable by a microprocessor from said first computer, said first computer algorithm being configured to allow said user to create a work order for said equipment and to transmit said work order to said second computer;a second computer algorithm executable by a microprocessor from said second computer, said second computer algorithm being configured to permit an operator to retrieve said work order, to integrate new field data into said work order, and to transmit information on completed work to said first computer; andsaid control subsystem being configured for positioning said working component relative to said work surface based on said work order.

13. The system according to claim 11, wherein said wireless connection between said first and second computers comprises a connection from the group consisting of: the Internet, a cloud-based connection, a local area network (LAN), and an intranet.

14. The system according to claim 12, wherein said first computer is configured for wireless connection to multiple pieces of equipment at one or more job sites.

15. The system according to claim 13, wherein said second computer comprises one of the group consisting of: an equipment-mounted virtual terminal, a laptop computer, a tablet computer, a smart phone, a desktop computer, and a netbook.

16. A method of controlling the position of a working component relative to a work surface, the working component including a global navigation satellite system (GNSS)-based positioning control subsystem; an inertial measurement unit (IMU) sensor mounted on the working component and connected to the control subsystem; one or more sensors associated with said working component and each configured for providing output comprising signal data corresponding to an operating or status condition; a processor connected to the control subsystem; the processor including a memory database configured for storing field data based on output from the GNSS, the IMU sensor, and the one or more sensors associated with the working component, which method includes the steps of: preprogramming said control subsystem for predetermined positioning parameters of said working component relative to said work surface;sensing inertial movements of said working component;processing positioning signals with said control subsystem;storing field data based on said GNSS, said IMU sensor, and said one or more sensors associated with said working component in said memory;accessing previous field data for said position parameters from said memory database;positioning said working component relative to said work surface based on said positioning signals and said field data; andapplying said field data to a terrain model stored in said processor.

17. The method according to claim 16, which includes the additional step of interconnecting multiple said working components with a centralized computer server.

18. The method according to claim 17, which includes the additional step of interconnecting said working components via the Internet.

19. The method according to claim 17, which includes the additional steps of coordinating the operation of multiple working components located remotely from each other and reporting the operations of said working components to said centralized computer server.

20. The method according to claim 16 wherein said working component comprises an agricultural spray boom and said positioning parameters include spray boom heights above said work surface based on a pre-processed terrain model.