This application claims priority to German Patent Application No. 10 2016 004 264.8, entitled “System for Digitally Supporting a Work Process,” filed Apr. 8, 2016, the entire contents of which are hereby incorporated by reference for all purposes.
The present disclosure relates to a system for digitally supporting a work process as well as to a corresponding method for its performance. The system supports cranes and construction machinery. The machine may be a construction machine or a crane and, in one example, a crawler-mounted crane, a hydraulic cable excavator, a pile driver or a drilling rig, an offshore crane, a ship crane and/or a harbor mobile crane.
A work process in larger projects is conventionally subjected to a complex planning process. First, a georeferenced 3D terrain model is prepared that maps the terrain on which the work process is to be carried out. Starting from this information, a work plan is prepared and passed on to partners and employees of other trades. They make their plans on the basis of the documents passed on to them.
It is problematic with this procedure that changes are not definitely passed on to the planners and changes resulting therefrom are not necessarily taken up into the work plan.
Changes could easily be lost by procedures typical in the prior art. It is thus possible, for example, that a lifting operation using a plurality of cranes only exists as a paper document and all machine operators are given verbal instructions. During the lifting operation, the operators are individually verbally instructed about the respective required driving movements of the individual crane. The operator only carries out individual instructions without knowing the underlying work plan in detail. It can also occur that the part work plans originating from different trades are not ideally coordinated with one another.
As can be seen for the example of a crane, it can therefore occur that with an imprecise assumption of conditions, the planning of the lifting operation, in particular of the parameters of payload, mass, center of gravity or geometrical dimensions, has to be carried out again. In addition, the processes have no continuous documentation and an analysis of the weak points is not possible in retrospect.
The present disclosure overcomes the disadvantages arising from the prior art in that it enables a direct transition of the work plan free of media disruptions from the means of the planning into the means of the simulation or into the means of the navigation support and control support. The disadvantages of the prior art are overcome by the present disclosure. It is possible to pass on a work plan to another planner such that the work plan is either locked for the preparer or such that the work plan is edited in a cooperative mode together by both sides. After the final editing of the work plan, it is communicated to the individual operators of machinery and/or to the coordinators of the work process.
As one embodiment, a system for digitally supporting a work process comprises a database for receiving different data and data types; a means for planning a work process that has access to the database and is configured to store a work plan in the database, with the work plan, in one embodiment, comprising the configuration of a machine (including tools such as hooks or special underground engineering tools); a description of the working environment, including an optional load as well as a plurality of worksteps; and a means for simulating the work plan that has access to the database and that is configured to output data for simulating the work plan and a means for navigation support and control support of a machine that has access to the database and that is configured to communicate specific data of the work plan from the database to an associated machine during and/or before the real implementation of the work plan, as well as means for analyzing the work plan that carries out an analysis using the present data of the database to carry out an optimization, in particular of the work plan, of the machine or of the driving behavior of the operator.
In this respect, the database is a storage location present locally or in a cloud for storing and polling data. It is thereby possible that every party involved in the work process has access to the latest work plan. Provision can in particular be made that the terrain on which the work process is to be implemented is provided to the database in a digital manner.
The means for planning a work process serves the preparation of a work plan that comprises the respective machine or machines (in the specific configuration), the environment (based on a georeferenced 3D model) and an optional load as well as the individual worksteps of the machine. The matching machine in the matching configuration is typically searched for or is directly selected by an experienced user in the planning, that is in the preparation of a work plan, for a specific task, such as a lifting operation. The available machines are stored in the database in this respect.
The system is configured in this respect such that depending on the user group (lessee, lessor, scheduler, planner), the different demands with respect to access, interface and function are prepared for the respective user group so that the respective information can be transmitted in dependence on the objective and kind of application. The main focus of a scheduler is thus much rather on faster and easier access to all the machines and all the available configurations of a vehicle fleet, whereas what is important for the planner is the import of 3D drawings and the ability to present the relevant parameters such as bearing load, payload, distance from the environment, etc. for all the individual steps such as a workstep or a lift, for example. In addition, the means for planning a work process can be configured such that an individual workstep such as a lift can be divided into a plurality of worksteps. A lifting operation can thus comprise information on the crane configuration, the environment, the load and the respective worksteps and can be stored in the database such that a later, more closely described simulation can access these data. The operation of one machine or of a plurality of machines can be planned using the means of the planning.
The means for simulating the work plan has access to the database such that a simulation can be carried out using the work plan or the steps of the work plan stored in the database. The means for simulation is accordingly configured to forward data, in particular the generated work plan, to a simulator or to generate a simulation environment itself and to output it to simulate individual worksteps or the entire work plan. It is possible that in this respect specific instructions are sent to the simulator for every workstep such that the operator of the simulator or the trainers of the simulation process have their attention drawn to a non-ideal design of a work plan (work plan or workstep) and such that thereupon a new, optimized routine is defined having its own worksteps or a changed configuration that is then stored in the database.
Non-ideally planned work plans and worksteps can already be recognized before the real execution and can be optimized in a very early stage with this procedure. The basis for this is, however, that both the means for simulation and the means for planning access a common database in which the data of the work plan are stored. It is of advantage if the data of a georeferenced 3D terrain model likewise form the basis of the work plan. The reliability of the data is particularly high since no problems in the manual conversion or in the up-to-dateness of the currently used information are hereby present and since the use of a common platform is possible without any media disruption.
The system furthermore has a means for analyzing the work plan in comparison with the received process data that carries out an analysis with reference to the existing data of the database to decide whether an optimization of the work plan stored in the database or an optimization of the machine by repair and/or maintenance or an optimization of the behavior of the operator of the system is proposed.
The acquired process data can, one example, be compared with the work plan to recognize a deviation from the work plan or to obtain indications of a reduced power of the machine.
Statements on the quality of the operator of the machine, of the work plan and of the machine can be given by the comparison of process data. The system can propose specific action recommendations on the basis of these statements.
In the event that the operator does not operate the machines ideally, the system could store a training task in the database optimized to the specific manner of driving of the operator that is then invoked on the start of a simulation of the respective operator.
If the reduced power is due to a defect of the machine, this circumstance can be stored in the database so that the system sends a communication to a corresponding mechanic.
In the case of a non-ideally planned work plan, the system prepares a specific proposal for an optimization of the work plan. The planner can make a decision during the planning of the work process or during a revision of an already planned work plan on whether the originally planned workstep is to be maintained or whether the optimizing option proposed by the system should be applied.
A work process is digitally supported by the system having the features described herein so that fewer errors or unforeseen events occur and the work process can thus be carried out more efficiently and more effectively.
With a system in accordance with the present disclosure, all the process participants have the same level of information and the work plan and the underlying data are always up to date. All the information is synchronized via the common database. The data exchange takes place without any media disruption.
A further means of the system serves for the navigation and control support of a machine in the real implementation of the work plan. In this respect, a work plan is uploaded into the machine before and/or during operation that supports the operator in navigating a machine.
If, for example, georeferenced 3D data are stored in the work plan, the exact position of a workstep to be performed can be determined and a navigation aid on this point can be offered to the operator. For the example of a crane this would mean that the planned slew angle of the superstructure and of the undercarriage or the luffing angle of the main boom and of the luffing boom or the required height of the hook is displayed to the machine operator. The system can furthermore display further additional planning information that allows the operator a better overview and a better processing of a workstep of the work plan. The weight of a load to be lifted and/or the sheeving of the hook ideal for this purpose to lift the load is/are displayed, for example.
The system furthermore comprises a means for receiving process data of the machine on the execution of the work plan that has access to the database and that is configured to receive process data of a machine.
The system furthermore, in one embodiment, comprises a means for the output of information for the operation coordinator. The means for the output of operation can be a tablet, for example. It has access to the database and is configured to provide relevant information via a work machine and to determine a deviation of a step from the work plan by a comparison of planning data with current data. The system is configured to access process/state/control parameters of a machine used for the real implementation of the work plan and to compare them with the work plan stored in the database. The system can furthermore be used to navigate the machine operator through the work plan of the machine and to display additional information to the machine operator.
The means for the output of information is typically designed as a mobile device and transmits the relevant information from the machine and from the database via a communication module (e.g. wireless LAN/GSM). In this respect, the work plan can be compared with the current data so that a coordinator recognizes deviations at an early time and can provide corresponding counter-measures. A tandem stroke/multiple stroke can be named as an example in this respect in which the work of a coordinator is decisively simplified while making use of the information provided by the means for the output of information. It is additionally conceivable that information on the setup, operation and maintenance of a machine is provided via this means.
In accordance with a further development of the present disclosure, the system is configured to generate all the information for the respective means on the basis of a common database and to enter all the information generated herefrom into the common database to avoid divergences in the database used for generating the information.
The work plan, in one embodiment, comprises a sequence of a plurality of worksteps that contribute in their totality to the completion of the planned work process. In this respect, a plurality of machines can be assigned to one work plan that are suitable for carrying out the respective workstep.
In accordance with a further modification of the present disclosure, a workstep furthermore comprises the position for carrying out the workstep on the terrain of the work process and/or further parameters that relate to the step that in particular include a bearing load, a payload, a distance from the environment as the parameters.
The means for simulating the work plan is, in one embodiment, associated with a simulator that simulates a machine to simulate and subsequently to optimize the worksteps provided in the work plan with the aid of the simulator. It is of advantage in this respect to recognize problems occurring in the simulation and to adapt the work plan accordingly. It is of advantage when the simulator simulates the machine provided for carrying out the work plan in the respective configuration. The simulator can in this respect simulate the machine suitable for the workstep and has the same control as the simulated machine as well as the same operating units (such as a joystick, a keyboard, a monitor). Through the interaction with an operator, said operator is already prepared for critical work in advance in the simulation and can locate improvements to the work plan through his experience that should then, in one embodiment, be introduced via the means of the planning.
The information of the means for navigation and control support are supplied to the device operator directly via a display unit in the operator's cabin. In one embodiment, this may be done by way of an “augmented reality” representation in which the real environment is shown together with additional information on a display unit.
It is also advantageous in this connection if the means for receiving process data of a machine is configured to detect parameters on the actual use of the machine and to store them in the database during the carrying out of a workstep of the work plan by a machine. This allows the analysis between the desired value and the actual value of the step in the construction plan.
In accordance with a further development of the present disclosure, the means for the analysis is configured to design an optimization of future worksteps of a work plan more efficiently using the existing data of the database.
Individual embodiments of the present disclosure will be looked at in detail in the following with the help of the Figures.
After completion of the planning, a simulation of the work plan can be carried out with the aid of the means 2 for simulation. In this respect, the three dimensional model of the environment and the worksteps to be simulated, including the relevant parameters such as the position and angle of the machine, the payload, bearing load, etc., are passed on to the means for simulation 2 by the means for planning 1. This takes place via a storing of data in the database 10.
The means 3 serves for the navigation and control support of a machine 12 in the real implementation of the work process. In this respect, the work plans, in one embodiment, already simulated in a simulation are therefore carried out in reality. To support an operator of a machine, the means 3 is configured to have the support data, in particular drive assistance data, displayed to the operator. The location at which the next workstep of the machine is to be carried out or which control function is to be carried out next can thus be displayed to the operator of the machine, for example. The direction of the machine to be controlled, information on the next workstep and/or further helpful information can also be displayed.
This can very specifically mean, for example, that which luffing angle the main boom has to adopt to carry out the next workstep in the work plan is displayed to a machine operator. The control support information is naturally not restricted to a crane or to the slewing of a main boom, but can rather comprise all the relevant control actions of a machine.
To have the information on the navigation support and control support supplied to the machine, substantially similar data are passed on to the means 2 for simulation. Instead of a simulation by an associated simulator, the real implementation of the worksteps of a work plan in contrast takes place by an operator or by the machine operated by the operator.
The means 4 for detecting state parameters and control parameters of a machine is configured to receive a plurality of process data of the machine on a carrying out of a workstep of the work plan.
This would mean with respect to the previously introduced example of a crane as the machine that the means 4 for process data detection communicates all the state parameters of a crane such as the slewing angle of the superstructure, the luffing angle of the main boom and/or of the luffing boom, the position of the hook and the like to the means 6 for analysis so that the system can carry out a previously described analysis.
After carrying out this analysis, the conclusions drawn therefrom are forwarded to the means 1 for planning to correct possibly incorrectly planned steps in the work plan.
There is furthermore means 5 for the output of information that provides relevant information on a machine and makes a deviation of a workstep from the work plan recognizable by a comparison of planning data with current data. This means can be implemented by a tablet. It is therefore possible for a coordinator who monitors the correct implementation of the work plan to immediately recognize and counteract possible deviations from the desired state in a particularly simple manner.
After a complete preparation of the work plan it can be exported in the form of a protocol by the means of the planning.
The results of the simulation or of the analysis that takes place after the carrying out of a step can again be input into the database or into the individual worksteps of the work plan. The machine configuration can be optimized in this respect or an ideal distance, an ideal payload capacity and/or an ideal bearing load can be achieved. It is advantageous that the planning reaches the operator 1:1, that the plan can be simulated and that coordination on the work plan can be provided for all those involved by means of visualization.
It is clear to the skilled person that the disadvantages known from the prior art are overcome with the aid of the system in accordance with the present disclosure for the digital support of a work process.
An exemplary scenario to illustrate the present disclosure will be shown in the following with reference to
The cloud 202, or the database, is used as the central data store and point of exchange between the different means. It organizes the data distribution and data updating or the access and exchange of data and projects. Projects can be exchanged (sequentially > that is, project utilization after one another or cooperatively during simultaneous work on the project) between different partners.
The potential client works with a version of the planning tool (means for planning, called “Crane planner”, e.g., crane planners 204, 205, and 207 shown in
Lessor B would like to safeguard himself and to discuss the project again with an external engineering office C. Lessor B starts a “cooperative project mode” and invites engineering office C to take part. Both lessor B and engineering office C thus see the project and all the changes simultaneously. Both can make changes to the project. If lessor B wants to prepare his machine operator for the complicated lifting task, the revised project is sent to the next closest simulator 206 for this purpose.
It is thus possible that the operator tests the planned project and notices that he cannot agree to the planning. In one embodiment, his desired changes are then worked into the project by the lessor B.
The lessor B presents the project with the aid of a tablet or of another mobile device to the operator and to the remaining participants directly on the construction site. As soon as the machine 208 is dispatched for the operation, the project is transferred to the machine 208. The operator starts the machine and receives a workstep list (including erection/assembly) that he has to carry out.
The lift of an object weighing 40 t is provided in the plan. The operator notices while hitching the load on the construction site that it is 42 t heavy. It is possible by the use of the present disclosure that he consults with the planner. The latter updates the mass of the load object to 42 t and checks the dependencies of this adaptation. He transmits the updated project to the machine 208 again. The machine 208 displays the DESIRED 42 t and the ACTUAL 42 t to the operator. It is thereby ensured that the further lifting takes place without problem.
It is subsequently possible to analyze the lift. As explained above, the results of the analysis 210 that takes place after the carrying out of a step can again be input into the database 202 or into the individual worksteps of the work plan. It can be recognized in this respect that the operator did not follow the plan and had an operating problem, for example, too jerky a lift of the load, oscillating movements. It is possible to present a training adapted to the operating problem and to send the operator to the simulator 206 again.
At the rear side of the superstructure 12 opposite the articulated connection point of the boom 54, the former carries an operating/superstructure ballast 58 which counteracts the tilting torque induced by the boom 54 or by a load suspended thereon.
The rearwardly directed derrick boom 55 is mounted behind the boom system 54, with the boom system 54 or the main boom head being guyed in a conventional manner via the adjustable guying 14 at the derrick boom 55.
It is necessary on the raising of very heavy loads to guy the derrick boom 55 via an additional derrick ballast. As a rule, a derrick ballast is used for this purpose which is suspended above the ground and which is here shown as a constant ballast 200 (alternatively referred to herein as a counter-weight arrangement 200).
Crane 50 further includes a crane control system 20, which is schematically shown in
The system shown in
Turning to
At 402, the method includes receiving data for planning a work process at a database. As described herein, the data may include a terrain on which the work process is to be carried out, one or more features or positions of the machine intended to carry out the work process, and/or tasks to be implemented by the machine. At 404, the method includes, creating a work plan based on the received data. The work plan may be created at one or more planning devices and/or at the database and then stored within the database. Additionally, the work plan may include one or more of a configuration of the machine, a description of a work environment of the machine, and a plurality of steps. At 406, the method optionally includes simulating the work plan via a simulator (such as the simulators described above) in communication with the database. Then, at 408, the method may optionally include updating the work plan stored at the database based on results of the simulation at 406.
At 410, the method includes implementing the created work plan at a designated machine or machines (e.g., such as crane 50 shown in
At 412, the method includes analyzing the work plan based on process data resulting from (e.g., generated as a result of) implementing the created work plan at the machine. For example, the control system of the machine may create process data from various sensors of the control system, during execution of the work plan, and then send the process data to the database where it may be analyzed there or at one or more of the planning devices (or an alternate computing device in communication with the database). The method at 414 includes updating the work plan stored at the database based on the analysis at 412. The updated work plan may then be stored at the database and used for future implementations of the work plan at one or more machines.
Number | Date | Country | Kind |
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10 2016 004 264.8 | Apr 2016 | DE | national |