ROTATIONAL MACHINES AND HAZARD WARNING METHODS THEREFOR

Abstract

A rotational machine includes a base operable to move the rotational machine, a body rotationally mounted on the base, one or more sensors coupled to the body, and a controller communicably coupled to the one or more sensors. The one or more sensors detect movement data of the rotational machine and location data of an object near the rotational machine. The controller is operable to perform a hazard warning method. The method includes applying a detection zone filter to the location data of the object based on the movement data of the rotational machine and annunciating an alert if the location data passes the detection zone filter.

Description

TECHNICAL FIELD

This disclosure relates generally to rotational machines and, more particularly, to hazard warning methods for rotational machines.

BACKGROUND

Certain mobile industrial machines, such as excavators and mining shovels, include an upper structure that can rapidly rotate. Other mobile industrial machines can rapidly change direction, for example wheel loaders, articulated tractors, and bulldozers. All of these systems may include hazard warning systems that may alert an operator to a potential hazard located near the rotational machine. However, many such systems suffer from false alerts and/or from alerts to objects too far from the rotational machine to pose a true hazard. Accordingly, such systems may generate an overabundance of alerts, incentivizing the operator to ignore or silence the alerts. This may cause the operator to miss or overlook genuine hazards.

CN114016567A (“the 567 patent”) discusses a remote control safety early warning system for people around an excavator. The system comprises a posture sensing device, a control device, an image acquisition device and an image processing device; the image acquisition device acquires images around the excavator and transmits the images to the image processing device; the image processing device identifies people in the images, calculates the distances from the people to the excavator and transmits the distances to the control device; the posture sensing device is connected to the control device; the control device is connected to the image acquisition device; the posture sensing device sends corresponding signals to the control device according to actions of an operating rod and a bucket rod; and the control device controls the image acquisition device to rotate to a corresponding position. The system does not, however, apply a detection zone filter to prioritize genuine hazards.

The rotational machines and methods of the present disclosure may solve one or more of the problems set forth above and/or other problems in the art. The scope of the current disclosure, however, is defined by the attached claims, and not by the ability to solve any specific problem.

SUMMARY

In one aspect, a rotational machine includes a base operable to move the rotational machine, a body rotationally mounted on the base, one or more sensors coupled to the body, and a controller communicably coupled to the one or more sensors. The one or more sensors detect movement data of the rotational machine and location data of an object near the rotational machine. The controller is operable to perform a hazard warning method. The method includes applying a detection zone filter to the location data of the object based on the movement data of the rotational machine and annunciating an alert if the location data passes the detection zone filter.

In another aspect, a method of providing a hazard warning to an operator of a rotational machine includes sensing object location data with one or more sensors coupled to the rotational machine, sensing machine movement data with the one or more sensors coupled to the rotational machine, applying a detection zone filter to the object location data based on the machine movement data, and providing an alert if the object location data passes the detection zone filter.

In another aspect, a method of providing a hazard warning to an operator of a rotational machine includes sensing object location data with one or more sensors coupled to the rotational machine, sensing machine rotational and speed data with the one or more sensors coupled to the rotational machine, applying a detection zone filter to the object location data based on the machine movement data, and alerting the operator if the object location data passes the detection zone filter.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various exemplary embodiments and together with the description, serve to explain the principles of the disclosed embodiments.

FIG. 1 is a perspective view of a rotational machine, according to aspects of the disclosure.

FIG. 2 is a top view of a the rotational machine of FIG. 1, according to aspects of the disclosure.

FIG. 3 is a schematic diagram of a control system of the rotational machine of FIG. 1, according to aspects of the disclosure.

FIG. 4 is a schematic diagram of a method of providing a hazard warning using the control system of FIG. 3, according to aspects of the disclosure.

DETAILED DESCRIPTION

Both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the features, as claimed. As used herein, the terms “comprises,” “comprising,” “having,” “including,” or other variations thereof, are intended to cover a non-exclusive inclusion such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements, but may include other elements not expressly listed or inherent to such a process, method, article, or apparatus. In this disclosure, relative terms, such as, for example, “about,” “substantially,” “generally,” and “approximately” are used to indicate a possible variation of +10% in a stated value or characteristic.

Referring to FIG. 1, an embodiment of a rotating machine 100 is schematically depicted. The rotational machine 100 may be, any machine that operates with full or partial rotating movement, including, for example, an excavator (as shown), a crane, rope shovel, dragline, mining shovel, wheel loader, articulated tractor, or a dozer. The rotating machine 100 may include a body 110 rotationally mounted on a base 111. The base 111 may include tracks 112 operable to move the rotating machine 100. The body 110 may include an operator station, cab, or enclose 108. Coupled to the body 110 may be an arm 106. The arm 160 may include a bucket 102 or other tool and may be articulated via hydraulic cylinders 104.

The rotating machine 100 may include one or more sensors 120, such as sensors 122, 124, and 126, and one or more output devices 130. The one or more sensors 120 may be cameras, position sensors, thermal sensors, or other sensors or a combination of such sensors. The one or more sensors 120 may be coupled to a roof or a top surface of the body 110, such as depicted. The one or more sensors 120 may be stationary or may be rotatably coupled to the body 110. As will be described in greater detail herein, the one or more sensors 120 may be operable to sense the position of a hazard, such as a nearby person, and relay the position of the hazard to a controller 220. In some embodiments, the one or more sensors 120 may include rotational and/or positional sensors coupled to the tracks 112 and/or the body 110. Accordingly, in some embodiments, the one or more sensors 120 may be operable to sense movement data of the rotational machine 100 or movement data of the body 110 relative to the base 111. The movement data of the rotational machine 100 may include both positional data and speed data. The one or more sensors 120 may be include sensors coupled to operator controls within the operator cab 108. Accordingly, in some embodiments, the one or more sensors 120 may be operable to sense intended movement data of the rotational machine 100.

The one or more output devices 130 may be coupled to the body 110, such as in or near the operator station 108 for the machine operator, and/or external to the body 110, such as for people in the vicinity of the machine 100. The one or more output devices 130 may be operable to communicate an audio and/or visual alert. For example, the one or more output devices 130 may include a speaker, a lamp, and/or a screen. In some embodiments, the one or more output devices 130 may include a display 128 within the operator station 108 and viewable by the operator.

Referring now to FIG. 2, the one or more sensors 120, individually or collectively, may be operable to sense the position of a hazard located in zones surrounding the rotating machine 100. In particular, the one or more sensors 120 may be operable to sense the position of a hazard in zones A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, and R, as depicted. For simplicity, the zones may be referenced collectively as “zones A-R.” The zones may include critical zones 142, located adjacent or closest to the rotating machine 100, and caution zones 140, surrounding the critical zones 142. As used herein, the term “critical” is used to verbally distinguish zones closer to the rotating machine 100 from “caution” zones, which are further from the rotating machine 100. The term “critical” is not used to indicate importance of a zone to the invention generally.

Referring now to FIG. 3 in combination with FIG. 1, a control system 200 for a rotating machine 100 may include a controller 220 communicably coupled to the one or more sensors 120 and the one or more output devices 130. The controller 220 may include any appropriate hardware, software, firmware, etc. to carry out the methods described in this disclosure, including the method of FIG. 4. The controller 220 may include one or more processors, memory, a secondary storage device, communication systems, and/or other appropriate hardware. The processors may be, for example, a single or multi-core processor, a digital signal processor, microcontroller, a general purpose central processing unit (CPU), a field programmable gate array (FPGA), a graphics processing unit (GPU), and/or other conventional processor or processing/controlling circuit or controller. The processors may embody microprocessors, for example, a single microprocessor or multiple microprocessors. The memory or secondary storage device associated with the controller 220 may be non-transitory computer-readable media that store data and/or software routines that may assist the controller 220 in performing its functions. In these aspects, the memory or secondary storage device may include, for example, read-only memory (ROM), random access memory (RAM), flash or other removable memory, or any other appropriate and conventional memory. Further, the memory or secondary storage device associated with controller 220 may also store data received from the various inputs or sensors associated with the rotational machine 100. Numerous commercially available microprocessors can be configured to perform the functions of the controller 220. It should be appreciated that the controller 220 could readily embody a general machine controller capable of controlling numerous other machine functions. Various other known circuits may be associated with controller 62, including signal-conditioning circuitry, communication circuitry, hydraulic or other actuation circuitry, and other appropriate circuitry.

Accordingly, the controller may receive inputs 202 from the one or more sensors 120 and may provide data corresponding to outputs 230 to the output devices 130. The inputs 202 may include, for example, forward movement data 204 related to the forward movement of the tracks 112, backward movement data 206 related to the backward movement of the tracks 112, left rotational movement data 208 related to a counter clockwise turn of the body 110, right rotational movement data 210 related to a clockwise turn of the body 110, and object sensor data 212 related to the location of a detected hazard. As will be described in greater detail herein, the controller 220 may filter the object sensor data 212 according to the movement data provided in the inputs 202. This filtering may occur by comparing the object sensor data 212 to known tables, maps, or values stored in the memory of the controller 220.

The outputs 230 may include, for example, an alert notification 234 related to an audio and/or visual warning and object detection zone display data 236 related to the zone within which the hazard was detected. The object detection zone display data 236 may be an output on a screen display such as a map with a positional indicator corresponding to the detected hazard or output text displaying a zone letter or other indicator.

Referring now to FIG. 4, in light of FIGS. 1-3, the controller 220 may be operable to perform a method 300 for providing a hazard warning to an operator 108. The method 300 may include a first step 302 of sensing object location data. In other words, the method 300 may include detecting object sensor data 212 with the one or sensors 120 and providing the object sensor data 212, or object location data, to the controller 220. This first step 302 may occur continuously.

The method 300 may include a second step 304 of sensing a machine movement. In other words, the method 300 may include detecting forward movement data 204, backward movement data 206, left rotational movement data 208 and/or right rotational movement data 210 with the one or more sensors 120 and providing the data to the controller 220. The forward movement data 204, backward movement data 206, left rotational movement data 208 and/or right rotational movement data 210 may include movement data of the body 110, the base 111, or both. As described hereinabove, in some embodiments, the one or more sensors 120 be coupled to operator controls and may detect intended machine movement. Accordingly, the second step 304 may include sensing intended machine movement instead of or in addition to actual machine movement. This second step 304 may occur continuously and may occur concurrently with the first step 302.

The method 300 may include a third step 306 of applying a detection zone filter to the object location data based on movement. When the controller 220 receives nonzero movement data (e.g. forward movement data 204, backward movement data 206, left rotational movement data 208 and/or right rotational movement data 210) from the one or more sensors 120, then the controller 220 may apply a filter to select relevant data of the object sensor data 212. More specifically, applying the filter may include selecting a subset of zones (such as the zones A-R) surrounding the rotational machine 100 and based on the movement data. Applying the filter may then include identifying the relevant data of the object sensor data 212 within the selected subset of zones. In some embodiments, the filter may include selecting only the caution zones 140, selecting only the critical zones 142, or selecting both caution zones 140 and critical zones 142.

For example, if the controller 220 receives backward movement data 206, then the zones D, E, F, M, N, and O (e.g. zones backward of the rotational machine 100) may be relevant. Accordingly, the controller 220 may apply a filter to the object sensor data 212 to select only object location data within those zones.

If the controller 220 receives left rotational movement data 208, then the zones A, B, R, and Q may be relevant as those are the zones into which the front (i.e., front corners) of the body 110, the arm 106, and/or a left track 112a may enter. Zones D, E, and G may be relevant as those are the zones into which the rear (i.e., rear corners) of the body 110, the left track 112a, and/or a right track 112b may enter. Accordingly, the controller 220 may apply a filter to the object sensor data 212 to select only object location within zones A, B, D, E, G, Q, and R.

If the controller 220 receives right rotational movement data 210, then the zones I, H, J and K may be relevant as those are the zones into which the front (front corners) of the body 110, the arm 106, and/or the right track 112b may enter. Zones F, E, and C may be relevant as those are the zones into which the rear (rear corners) of the body 110, the left track 112a, and/or the right track 112b may enter. Accordingly, the controller 220 may apply a filter to the object sensor data 212 to select only object location within zones C, E, F, H, I, J, and K.

Referring still to FIG. 4, in light of FIGS. 1-3, in some embodiments, the third step 306 may include applying a detection zone filter based on a speed of the rotational machine 100. As described above, in some circumstances, if the controller 220 receives backward movement data 206, then a filter may be applied to select object sensor data 212 corresponding to the zones D, E, F, M, N, and O. This may be true for a given backward movement speed. If, however, the controller 220 receives backward movement data 206 including a slow movement speed (e.g., less than 2 mph or less than 5 mph), then a filter may be applied to select object sensor data 212 corresponding to the zones D, E, and F, which are closer to the detected movement of the rotational machine 100. The zones M, N, and O, which are further away from the detected movement may be excluded by the filter.

As another example, if the controller 220 receives left rotational movement data 208 corresponding to a default speed, then a filter may be applied to select object sensor data 212 corresponding to the zones A, B, D, E, G, Q, and R, such as described above. If the controller 220 receives left rotational movement data 208 corresponding to a slower speed, then a filter may be applied to select object sensor data 212 corresponding to the zones A, D, G, and R, which are closer to the detected movement of the rotational machine 100. The zones B, Q, and E, which are further away from the detected movement may be excluded by the filter. In a similar manner, if the controller 220 receives left rotational movement data 208 corresponding to a faster speed, then a filter may be applied to select object sensor data 212 corresponding to the zones F and H in addition to zones A, B, D, E, G, Q, and R.

Referring still to FIG. 4, in light of FIGS. 1-3, after the object location data has been filtered according to the third step 306, the method 300 may include a fourth step 308 of annunciating an alert if the object is detected in the detection zone (i.e. if the object location data passes the detection zone filter). In other words, when the controller 220 identifies object sensor data 212 that is relevant according to the applied filter, then the controller 220 may output an alert notification 234 and/or object detection zone display data 236 as described hereinabove. In some embodiments, the alert may be an audio alert, a visual alert, or both. Accordingly, the operator 108 may be made aware of a relevant hazard. If no object location data passes the detection zone filter, then no alert may be annunciated.

As will now be appreciated, by filtering the object location data according to the third step 306, the outputs 230, such as an alert notification 234 and/or object detection zone display data 236, may be provided only when a hazard is relevant to present movement of the rotational machine 100. In this way, the method 300 may avoid providing an overwhelming number of alerts and may instead limit alerts to those indicating a hazard within a relevant location. This may encourage better operator attention to the alerts.

In some embodiments, the form of output 230 may vary by zone. Specifically, the method 300 may include identifying whether the object detection data corresponds to one of the caution zones 140 or one of the critical zones 142 and providing an alert based on the identified zone. For example, the one or more output devices 130 may display object detection zone display data 236 when the controller 220 identifies relevant object sensor data 212 within one of the caution zones 140 but may both display object detection zone data 236 and audibly provide an alert notification 234 when the controller 220 identifies relevant object sensor data 212 within one of the critical zones 142. This may encourage better operator attention to the alerts derived from a detected hazard in the critical zones 142, which are closer to the rotational machine 100.

Referring still to FIG. 4, in light of FIGS. 1-3, after the object location data has been filtered according to the third step 306, the method 300 may include a step 310 of altering machine movement. In particular, if the controller 220 identifies object sensor data 212 that is relevant according to the applied filter, then the controller 220 may slow, stop, or prevent movement of the machine 100. Such control of the movement of the machine 100 may function as an alert to the operator instead of or in addition to an audio or visual alert as described with respect to step 308. In some embodiments, the controller 220 may alter movement of the machine 100 if the controller 220 identifies object sensor data 212 that is relevant according to the applied filter and is within one of the critical zones 142. In some such embodiments, movement data within the caution zones may not be considered. By altering the movement of the machine 100, unintentional contact between the machine 100 and a detected object within the path of the machine 100 may be prevented. In embodiments wherein intended movement data is collected, the controller 220 may prevent movement of the machine 100 from occurring if the controller 220 identifies object sensor data 212 that is relevant according to the applied filter and is within one of the critical zones 142.

It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed device without departing from the scope of the disclosure. Other embodiments of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.

Claims

1. A rotational machine comprising: a base operable to move the rotational machine;a body rotationally mounted on the base;one or more sensors coupled to the body, wherein the one or more sensors detect movement data of the rotational machine and location data of an object near the rotational machine; anda controller communicably coupled to the one or more sensors, the controller operable to perform a hazard warning method, the method comprising:applying a detection zone filter to the location data of the object based on the movement data of the rotational machine; andproviding an alert if the location data passes the detection zone filter.

2. The rotational machine of claim 1, wherein applying a detection zone filter includes selecting a subset of zones surrounding the rotational machine based on the movement data.

3. The rotational machine of claim 2, wherein applying a detection zone filter further comprises identifying relevant object location data corresponding to the selected subset of zones.

4. The rotational machine of claim 3, wherein the method further comprises categorizing whether the relevant object location data is within a critical zone.

5. The rotational machine of claim 4, wherein annunciating an alert includes at least one of providing an audio warning; or displaying object detection zone data if the relevant object location data is within the critical zone.

6. The rotational machine of claim 3, wherein the method further comprises categorizing whether the relevant object location data is within a caution zone surrounding a critical zone.

7. The rotational machine of claim 6, wherein annunciating an alert includes only displaying object detection zone data if the relevant object location data is within the caution zone.

8. The rotational machine of claim 2, wherein selecting a subset of zones based on the movement data comprises selecting a first subset of zones positioned backward of the rotational machine when the movement data is indicative of a backward motion of the rotational machine.

9. The rotational machine of claim 2, selecting a subset of zones based on the movement data comprises selecting the subset based on at least one of forward movement data, backward movement data, left rotational movement data, right rotational movement data, or speed data.

10. The rotational machine of claim 1, wherein annunciating an alert comprises displaying object detection zone data.

11. A method of providing a hazard warning to an operator of a rotational machine, the method comprising: sensing object location data with one or more sensors coupled to the rotational machine;sensing machine movement data with the one or more sensors coupled to the rotational machine;applying a detection zone filter to the object location data based on the machine movement data; andproviding an alert if the object location data passes the detection zone filter.

12. The method of claim 11, wherein applying a detection zone filter includes selecting a subset of zones surrounding the rotational machine based on the movement data.

13. The method of claim 12, wherein applying a detection zone filter further comprises identifying object location data corresponding to the selected subset of zones.

14. The method of claim 11, wherein the method further includes sorting the object location data into a critical zone or a caution zone surrounding the critical zone if the location data passes the detection zone filter.

15. The method of claim 14, wherein providing the alert comprises one of preventing, slowing, or stopping movement of the rotational machine if the location data is within the critical zone.

16. The method of claim 14, wherein providing an alert comprises only providing a visual alert if the location data is within the caution zone.

17. The method of claim 14, wherein providing an alert comprises providing an audio alert and a visual alert if the location data is within the critical zone.

18. The method of claim 11, further comprising altering the movement of the machine if the object location data passes the detection zone filter.

19. A method of providing a hazard warning to an operator of a rotational machine, the method comprising: sensing object location data with one or more sensors coupled to the rotational machine;sensing machine rotational and speed data with the one or more sensors coupled to the rotational machine;applying a detection zone filter to the object location data based on the machine rotational and speed data; andalerting the operator if the object location data passes the detection zone filter.

20. The method of claim 19, wherein applying a detection zone filter includes selecting a subset of zones surrounding the rotational machine based on the machine rotational and speed data.