WORK MACHINE CONTROL SYSTEM, WORK MACHINE, AND METHOD FOR CONTROLLING WORK MACHINE

Abstract

A distance calculation unit calculates a first distance that is a distance between a first bucket point being a point on a bucket and a target design surface representing a target shape of an excavation target. The distance calculation unit calculates a second distance that is a distance between the target design surface and a second bucket point. The second bucket point is on the bucket on a straight line passing through the first bucket point and is parallel to an edge of the bucket. A tilt control unit compares the first distance and the second distance to calculate a tilt control amount to rotate the bucket around a tilt axis.

Description

The present disclosure relates to a work machine control system, a work machine, and a work machine control method.

BACKGROUND INFORMATION

A tilt bucket of which the angle with respect to an operating plane of work equipment is adjustable has been known as a bucket attached to a hydraulic excavator (for example, refer to Japanese Unexamined Patent Application, First Publication No. 2014-74319). The tilt bucket is configured to be rotatable around a bucket axis orthogonal to the operating plane and to be rotatable around a tilt axis orthogonal to the bucket axis.

SUMMARY

By the way, in a work machine such as a hydraulic excavator, a technique has been known that automatically controls work equipment such that a bucket moves along a target design surface representing a target shape of an excavation target. Also in the tilt bucket disclosed in Japanese Unexamined Patent Application, First Publication No. 2014-74319, it is desirable that the work equipment is automatically controlled such that the tilt bucket moves along the target design surface.

An object of the present disclosure is to provide a work machine control system which automatically controls work equipment such that a tilt bucket moves along a target design surface, a work machine, and a method for controlling a work machine.

According to one aspect of the present invention, a control system for a work machine is provided including a boom rotatable around a boom axis, an arm rotatable around an arm axis parallel to the boom axis, and a bucket rotatable around a bucket axis parallel to the arm axis and rotatable around a tilt axis orthogonal to the bucket axis, the system including: a distance calculation unit configured to calculate a first distance that is a distance between a first bucket point being a point on the bucket and a target design surface representing a target shape of an excavation target, and a second distance that is a distance between the target design surface and a second bucket point, the second bucket point being a point on the bucket on a straight line passing through the first bucket point and being parallel to an edge of the bucket; and a tilt control unit configured to calculate a tilt control amount to rotate the bucket around the tilt axis, based on at least a larger value of the first distance and the second distance.

According to the aspect, the control system for a work machine is capable of automatically controlling the work equipment such that the tilt bucket moves along the target design surface.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a view showing an example of a posture of a work machine and work equipment.

FIG. 2 is a schematic view showing a configuration of a work machine according to a first embodiment.

FIG. 3 is a front view showing a configuration of a bucket according to the first embodiment.

FIG. 4 is a view showing an internal configuration of a cab according to the first embodiment.

FIG. 5 is a schematic block diagram showing a configuration of a control device according to the first embodiment.

FIG. 6 is a flowchart showing operation of the control device according to the first embodiment.

FIG. 7 is a view showing a relationship between a target design surface and a point on an edge in automatic tilt control.

FIG. 8 is a view showing an example of a tilt function showing a relationship between a bucket distance difference and a target value of a tilt angular speed according to the first embodiment.

DESCRIPTION OF EMBODIMENTS

<Coordinate System>

FIG. 1 is a view showing an example of a posture of a work machine 100 and work equipment 150.

In the following description, a three-dimensional site coordinate system (Xg, Yg, Zg) and a three-dimensional vehicle body coordinate system (Xm, Ym, Zm) are defined, and a positional relationship will be described based on these coordinate systems.

The site coordinate system is a coordinate system including an Xg axis extending north-south, a Yg axis extending east-west, and a Zg axis extending in a vertical direction with the position of a global navigation satellite system (GNSS) reference station provided at a construction site as a reference point. An exemplary example of GNSS is global positioning system (GPS). Incidentally, in another embodiment, a global coordinate system represented by latitude and longitude and the like may be used instead of the site coordinate system.

The vehicle body coordinate system is a coordinate system including an Xm axis extending front and back, a Ym axis extending left and right, and a Zm axis extending up and down with respect to a representative point O defined in a swing body 130 of the work machine 100 when viewed from a seating position of an operator in a cab 170 to be described later. With respect to the representative point O of the swing body 130, the front is referred to as a +Xm direction, the rear is referred to as a −Xm direction, the left is referred to as a +Ym direction, the right is referred to as a −Ym direction, an up direction is referred to as a +Zm direction, and a down direction is referred to as a −Zm direction.

The site coordinate system and the vehicle body coordinate system can be converted to each other by specifying a position and a tilt of the work machine 100 in the site coordinate system.

First Embodiment

<<Configuration of Work Machine 100>>

FIG. 2 is a schematic view showing a configuration of the work machine 100 according to a first embodiment.

The work machine 100 operates at a construction site to construct an excavation target, such as earth. The work machine 100 according to the first embodiment is a hydraulic excavator.

The work machine 100 includes an undercarriage 110, the swing body 130, the work equipment 150, the cab 170, and a control device 190.

The undercarriage 110 supports the work machine 100 so as to be capable of traveling. The undercarriage 110 is, for example, a pair of left and right endless tracks. The swing body 130 is supported by the undercarriage 110 so as to be swingable around a swing center. The work equipment 150 is driven by hydraulic pressure. The work equipment 150 is supported by a front portion of the swing body 130 so as to be drivable in an up-down direction. The cab 170 is a space in which an operator gets on and operates the work machine 100. The cab 170 is provided at a front portion of the swing body 130. The control device 190 controls the undercarriage 110, the swing body 130, and the work equipment 150 based on an operation of the operator. The control device 190 is provided, for example, inside the cab 170.

<<Configuration of Swing Body 130>>

As shown in FIG. 2, the swing body 130 includes a position and azimuth direction detector 131 and a tilt detector 132.

The position and azimuth direction detector 131 computes a position of the swing body 130 in the site coordinate system, and an azimuth direction where the swing body 130 faces. The position and azimuth direction detector 131 includes two antennas that receive positioning signals from artificial satellites forming the GNSS. The two antennas are installed at different positions on the swing body 130. For example, the two antennas are provided in a counterweight portion of the swing body 130. The position and azimuth direction detector 131 detects a position of the representative point O of the swing body 130 in the site coordinate system based on a positioning signal received by at least one of the two antennas. The position and azimuth direction detector 131 detects an azimuth direction where the swing body 130 faces in the site coordinate system, using a positioning signal received by each of the two antennas.

The tilt detector 132 measures an acceleration and an angular speed of the swing body 130, and detects a tilt of the swing body 130 (for example, a roll representing rotation with respect to the Xm axis and a pitch representing rotation with respect to the Ym axis) based on the measurement result. The tilt detector 132 is installed, for example, below the cab 170. An exemplary example of the tilt detector 132 is an inertial measurement unit (IMU).

<<Configuration of Work Equipment 150>>

As shown in FIG. 2, the work equipment 150 includes a boom 151, an arm 152, a first link 153, a second link 154, and a bucket 155.

A base end portion of the boom 151 is attached to the swing body 130 via a boom pin P1. Hereinafter, a central axis of the boom pin P1 is referred to as a boom axis X1.

The arm 152 connects the boom 151 and the bucket 155. A base end portion of the arm 152 is attached to a distal end portion of the boom 151 via an arm pin P2. Hereinafter, a central axis of the arm pin P2 is referred to as an arm axis X2.

A first end of the first link 153 is attached to a side surface on a distal end side of the arm 152 via a first link pin P3. A second end of the first link 153 is attached to a first end of the second link 154 via a bucket cylinder pin P4.

The bucket 155 includes an edge that excavates earth or the like, and an accommodating portion that accommodates the excavated earth. A base end portion of the bucket 155 is attached to a distal end portion of the arm 152 via a bucket pin P5. Hereinafter, a central axis of the bucket pin P5 is referred to as a bucket axis X3. In addition, a base end portion of the bucket 155 is attached to a second end of the second link 154 via a second link pin P6.

The boom axis X1, the arm axis X2, and the bucket axis X3 are parallel to each other.

The work equipment 150 includes a plurality of hydraulic cylinders that are actuators for generating power. Specifically, the work equipment 150 includes a boom cylinder 156, an arm cylinder 157, and a bucket cylinder 158.

The boom cylinder 156 is a hydraulic cylinder that drives the boom 151. A base end portion of the boom cylinder 156 is attached to the swing body 130. A distal end portion of the boom cylinder 156 is attached to the boom 151. The boom cylinder 156 is provided with a boom cylinder stroke sensor 1561 that detects a stroke amount of the boom cylinder 156.

The arm cylinder 157 is a hydraulic cylinder that drives the arm 152. A base end portion of the arm cylinder 157 is attached to the boom 151. A distal end portion of the arm cylinder 157 is attached to the arm 152. The arm cylinder 157 is provided with an arm cylinder stroke sensor 1571 that detects a stroke amount of the arm cylinder 157.

The bucket cylinder 158 is a hydraulic cylinder that drives the bucket 155. A base end portion of the bucket cylinder 158 is attached to arm 152. A distal end portion of the bucket cylinder 158 is attached to the second end of the first link 153 and to the first end of the second link 154 via the second link pin P6. The bucket cylinder 158 is provided with a bucket cylinder stroke sensor 1581 that detects a stroke amount of the bucket cylinder 158.

<<Configuration of Bucket 155>>

FIG. 3 is a front view showing a configuration of the bucket 155 according to the first embodiment.

The bucket 155 according to the first embodiment is a tilt bucket that is rotatable around a tilt axis X4 that is an axis orthogonal to the bucket axis X3.

As shown in FIG. 3, the bucket 155 includes a bucket body 161, a joint 162, and a tilt cylinder 163.

A base end portion of the joint 162 is provided with a front bracket 1621 having an attachment hole for attaching the arm 152 via the bucket pin P5 and with a rear bracket 1622 having an attachment hole for attaching the second link 154 via the second link pin P6. In other words, the attachment hole of the front bracket 1621 is provided to pass through the bucket axis X3.

A distal end portion of the joint 162 is attached to a base end portion of the bucket body 161 via a tilt pin P7. The tilt pin P7 is provided to be orthogonal to the bucket axis X3. A central axis of the tilt pin P7 forms the tilt axis X4.

A tilt bracket 1611 for attaching the tilt cylinder 163 is provided at one end (left end or right end) of a base end portion of the bucket body 161.

The tilt cylinder 163 is a hydraulic cylinder that rotates the bucket body 161 around the tilt axis X4. A base end portion of the tilt cylinder 163 is attached to the tilt bracket 1611 via a tilt cylinder end pin P8. A distal end portion of the tilt cylinder 163 is attached to the joint 162 via a tilt cylinder top pin P9. The tilt cylinder end pin P8 and the tilt cylinder top pin P9 each are provided parallel to the tilt pin P7. Accordingly, the bucket body 161 is rotated around the tilt axis X4 by the driving of the tilt cylinder 163.

The tilt cylinder 163 is provided with a tilt cylinder stroke sensor 1631 that detects a stroke amount of the tilt cylinder 163.

<<Configuration of Cab 170>>

FIG. 4 is a view showing an internal configuration of the cab according to the first embodiment.

As shown in FIG. 4, a driver seat 171, an operation device 172, and the control device 190 are provided inside the cab 170.

The operation device 172 is an interface through which the undercarriage 110, the swing body 130, and the work equipment 150 are driven by a manual operation of the operator. The operation device 172 includes a left operation lever 1721, a right operation lever 1722, a left foot pedal 1723, a right foot pedal 1724, a left traveling lever 1725, and a right traveling lever 1726.

The left operation lever 1721 is provided on a left side of the driver seat 171. The right operation lever 1722 is provided on a right side of the driver seat 171.

The left operation lever 1721 is an operation mechanism that causes the swing body 130 to make a swing movement and causes the arm 152 to make a pulling movement and a pushing movement. Specifically, when the operator tilts the left operation lever 1721 forward, the arm cylinder 157 is driven and the arm 152 is pushed. In addition, when the operator tilts the left operation lever 1721 backward, the arm cylinder 157 is driven and the arm 152 is pulled. In addition, when the operator tilts the left operation lever 1721 in a right direction, the swing body 130 swings rightward. In addition, when the operator tilts the left operation lever 1721 in a left direction, the swing body 130 swings leftward.

The right operation lever 1722 is an operation mechanism that causes the bucket 155 to make an excavating movement and a dumping movement and causes the boom 151 to make a rising movement and a lowering movement. Specifically, when the operator tilts the right operation lever 1722 forward, the boom cylinder 156 is driven to cause the boom 151 to make a lowering movement. In addition, when the operator tilts the right operation lever 1722 backward, the boom cylinder 156 is driven to cause the boom 151 to make a rising movement. In addition, when the operator tilts the right operation lever 1722 in the right direction, the bucket cylinder 158 is driven to cause the bucket 155 to make a dumping movement. In addition, when the operator tilts the right operation lever 1722 in the left direction, the bucket cylinder 158 is driven to cause the bucket 155 to make an excavating movement.

Incidentally, a relationship between operating directions of the left operation lever 1721 and the right operation lever 1722, a movement direction of the work equipment 150, and a swing direction of the swing body 130 may not be the above-described relationship.

In addition, a tilt operation button (not shown) is provided at an upper portion of the right operation lever 1722. Specifically, when the operator slides the tilt operation button in the left direction, the tilt cylinder 163 is driven and the bucket 155 is tilted and rotated in the left direction when viewed from the operator. When the operator slides the tilt operation button in the right direction, the tilt cylinder 163 is driven and the bucket 155 is tilted and rotated in the right direction when viewed from the operator.

Incidentally, the tilt operation button may be configured to be rotated in a left-right direction. In addition, a tilt operation may be realized by operation of a pedal (not shown) performed by the operator.

The left foot pedal 1723 is disposed on a left side of a floor surface in front of the driver seat 171. The right foot pedal 1724 is disposed on a right side of the floor surface in front of the driver seat 171. The left traveling lever 1725 is pivotally supported by the left foot pedal 1723, and is configured such that the tilt of the left traveling lever 1725 and the press down of the left foot pedal 1723 are linked to each other. The right traveling lever 1726 is pivotally supported by the right foot pedal 1724, and is configured such that the tilt of the right traveling lever 1726 and the press down of the right foot pedal 1724 are linked to each other.

The left foot pedal 1723 and the left traveling lever 1725 correspond to rotational drive of a left crawler belt of the undercarriage 110. Specifically, in a case where drive wheels of the undercarriage 110 are disposed at the rear, when the operator tilts the left foot pedal 1723 or the left traveling lever 1725 forward, the left crawler belt rotates in a forward direction. In addition, when the operator tilts the left foot pedal 1723 or the left traveling lever 1725 backward, the left crawler belt rotates in a backward direction.

The right foot pedal 1724 and the right traveling lever 1726 correspond to rotational drive of a right crawler belt of the undercarriage 110. Specifically, in a case where the drive wheels of the undercarriage 110 are disposed at the rear, when the operator tilts the right foot pedal 1724 or the right traveling lever 1726 forward, the right crawler belt rotates in the forward direction. In addition, when the operator tilts the right foot pedal 1724 or the right traveling lever 1726 backward, the right crawler belt rotates in the backward direction.

<<Configuration of Control Device 190>>

The control device 190 limits movement of the bucket 155 in a direction toward an excavation target such that the bucket 155 does not intrude on a target design surface set at the construction site. The target design surface represents the target shape of the excavation target. Limitation of the movement of the bucket 155 by the control device 190 based on the target design surface is also referred to as intervention control.

Intervention control when the operator performs only a pulling operation of the arm 152 to perform ground leveling work at the construction site will be described. When the distance between the bucket 155 and the target design surface is less than a predetermined intervention control distance, the control device 190 generates an operation signal of the boom cylinder 156 according to a distance between the edge of the bucket 155 and the target design surface that is involved in a movement of the arm 152, such that the bucket 155 does not intrude on the target design surface. Accordingly, the operator simply performs an operation to move the arm 152, to cause the control device 190 to generate an operation signal of the boom cylinder 156 and the boom 151 is automatically raised, so that the movement of the bucket 155 is limited and the edge of the bucket 155 is automatically prevented from intruding on the design surface.

Incidentally, in another embodiment, the control device 190 may generate a control command for the arm cylinder 157 or a control command for the bucket cylinder 158 in the intervention control. In other words, in another embodiment, the speed of the bucket 155 may be limited by raising the arm 152 or the speed of the bucket 155 may be directly limited in the intervention control.

In addition, when the distance between the bucket 155 and the target design surface is less than a predetermined tilt control distance, the control device 190 causes the bucket 155 to rotate around the tilt axis X4 such that the edge of the bucket 155 and the target design surface are parallel to each other. Control in which the control device 190 causes the bucket 155 to rotate around the tilt axis X4 based on the target design surface is also referred to as automatic tilt control.

FIG. 5 is a schematic block diagram showing a configuration of the control device 190 according to the first embodiment.

The control device 190 is a computer including a processor 210, a main memory 230, a storage 250, and an interface 270.

The storage 250 is a non-transitory physical storage medium. Exemplary examples of the storage 250 include magnetic disks, optical disks, magneto-optical disks, semiconductor memories, and the like. The storage 250 may be an internal medium that is directly connected to a bus of the control device 190 or may be an external medium connected to the control device 190 via the interface 270 or via a communication line. The storage 250 stores a program for controlling the work machine 100.

The program may realize some of functions to be exhibited by the control device 190. For example, the program may exhibit functions in combination with another program that is already stored in the storage 250 or in combination with another program installed in another device. Incidentally, in another embodiment, the control device 190 may include a custom large scale integrated circuit (LSI) such as a programmable logic device (PLD) in addition to the above configuration or instead of the above configuration. Exemplary examples of the PLD include a programmable array logic (PAL), a generic array logic (GAL), a complex programmable logic device (CPLD), and a field programmable gate array (FPGA). In this case, some or all of the functions to be realized by the processor may be realized by the integrated circuit.

Design surface data indicating the target design surface is stored in the storage 250 in advance. The design surface data is three-dimensional data represented by the site coordinate system, and is represented by a plurality of triangular polygons. The triangular polygons forming the design surface data have sides shared with other triangular polygons adjacent thereto. In other words, the design surface data represents a continuous plane formed of a plurality of planes. Incidentally, in another embodiment, the design surface data may be formed of polygonal surfaces other than triangular polygons, or may be represented in another format such as point cloud data.

Incidentally, in the present embodiment, the design surface data is stored in the storage 250, but the present invention is not limited to this configuration. The design surface data may be downloaded from an external memory or a server (not shown) via a communication line (not shown).

The processor 210 executes the program to function as a detection value acquisition unit 211, a bucket position specification unit 212, a target plane determination unit 213, a distance calculation unit 214, an operation amount acquisition unit 215, an intervention control unit 216, a tilt control unit 217, and an output unit 218.

The detection value acquisition unit 211 acquires a detection value of each of the boom cylinder stroke sensor 1561, the arm cylinder stroke sensor 1571, the bucket cylinder stroke sensor 1581, the tilt cylinder stroke sensor 1631, the position and azimuth direction detector 131, and the tilt detector 132. In other words, the detection value acquisition unit 211 acquires a position of the swing body 130 in the site coordinate system, an azimuth direction where the swing body 130 faces, a tilt of the swing body 130, a stroke length of the boom cylinder 156, a stroke length of the arm cylinder 157, a stroke length of the bucket cylinder 158, and a stroke length of the tilt cylinder 163.

The bucket position specification unit 212 specifies positions of a plurality of points on the edge of the bucket 155 based on the detection values acquired by the detection value acquisition unit 211. For example, the bucket position specification unit 212 specifies positions of five points that divide the edge of the bucket 155 into four equal segments. A method for specifying a position of the edge of the bucket 155 will be described later.

The target plane determination unit 213 determines a target plane that is a target of tilt control. The target plane is a plane passing through at least one of the plurality of triangular polygons forming the target design surface. Specifically, the target plane determination unit 213 determines the target plane according to the following procedure. The target plane determination unit 213 calculates a distance between each point of the plurality of points and a triangular polygon facing the each point among the triangular polygons forming the target design surface, based on the design surface data and the positions of the plurality of points specified by the bucket position specification unit 212. At this time, the plurality of points may face different triangular polygons. The target plane determination unit 213 specifies a triangular polygon related to a shortest distance, and determines a plane passing through the triangular polygon, as the target plane.

The distance calculation unit 214 calculates distances between the plurality of points and the target plane based on the positions of the plurality of points specified by the bucket position specification unit 212 and the target plane determined by the target plane determination unit 213.

The operation amount acquisition unit 215 acquires an operation signal indicating an operation amount from the operation device 172. The operation amount acquisition unit 215 acquires at least an operation amount related to a rising operation and a lowering operation of the boom 151, an operation amount related to a pushing operation and a pulling operation of the arm 152, and an operation amount related to an excavating operation, a dumping operation, and a tilt operation of the bucket 155.

The intervention control unit 216 performs the intervention control of the work equipment 150 based on the operation amount of the operation device 172 acquired by the operation amount acquisition unit 215 and the shortest distance among the distances calculated by the distance calculation unit 214.

The tilt control unit 217 performs the automatic tilt control based on a difference between a first distance that is a distance from a left end of the edge of the bucket 155 to the target plane and a second distance that is a distance from a right end of the edge of the bucket 155 to the target plane, among the distances calculated by the distance calculation unit 214. The left end and the right end of the edge of the bucket 155 are one example of a first bucket point and of a second bucket point. Incidentally, in another embodiment, the first bucket point and the second bucket point may be other points on the bucket 155. However, the condition that the second bucket point passes through the first bucket point and exists on a straight line parallel to the edge of the bucket 155 has to be satisfied. In other words, in another embodiment, the first bucket point and the second bucket point may be points on a bottom surface, and may not necessarily be points on the edge.

The output unit 218 outputs a control signal to each actuator based on the operation amount acquired by the operation amount acquisition unit 215 and the tilt control amount calculated by the tilt control unit 217.

<<Method for Specifying Position of Edge of Bucket 155>>

Here, a method for specifying a position of the edge of the bucket 155 using the bucket position specification unit 212 will be described with reference to FIGS. 1 and 3. A position of the edge of the bucket 155 in the vehicle body coordinate system can be specified by a boom length L1, an arm length L2, a joint length L3, a bucket length L4, a boom relative angle α, an arm relative angle β, a bucket relative angle γ, a tilt angle η, a position of the boom pin P1 in the vehicle body coordinate system, and a position of the representative point O in the site coordinate system.

The boom length L1 is a known length from the boom pin P1 to the arm pin P2.

The arm length L2 is a known length from the arm pin P2 to the first link pin P3.

The joint length L3 is a known length from the first link pin P3 to the tilt pin P7.

The bucket length L4 is a known length from the tilt pin P7 to a center point of the edge of the bucket 155.

The boom relative angle α is represented by an angle formed by a half line extending from the boom pin P1 in the up direction (+Zm direction) of the swing body 130 and a half line extending from the boom pin P1 to the arm pin P2. Incidentally, as shown in FIG. 1, the up direction (+Zm direction) of and a vertical up direction (+Zg direction) of the swing body 130 do not necessarily coincide with each other due to a tilt θ of the swing body 130.

The arm relative angle β is represented by an angle formed by a half line extending from the boom pin P1 to the arm pin P2 and a half line extending from the arm pin P2 to the first link pin P3.

The bucket relative angle γ is represented by an angle formed by a half line extending from the arm pin P2 to the first link pin P3 and a half line extending from the first link pin P3 to the tilt pin P7.

The tilt angle η is represented by an angle formed by a half line extending from the tilt pin P7 in a direction orthogonal to the first link pin P3 and to the tilt pin P7 and a half line extending from the tilt pin P7 to the center point of the edge of the bucket 155.

The position of the edge of the bucket 155 in the site coordinate system is specified according to, for example, the following procedure. The bucket position specification unit 212 specifies the position of the arm pin P2 in the vehicle body coordinate system based on the position of the boom pin P1 in the vehicle body coordinate system, the boom relative angle α, and the boom length L1. The bucket position specification unit 212 specifies the position of the first link pin P3 in the vehicle body coordinate system based on the position of the arm pin P2 in the vehicle body coordinate system, the arm relative angle β, and the arm length L2. The bucket position specification unit 212 specifies the position of the tilt pin P7 in the vehicle body coordinate system based on the position of the first link pin P3 in the vehicle body coordinate system, the bucket relative angle γ, and the joint length L3. The bucket position specification unit 212 specifies the position of the center point of the edge of the bucket 155 in the vehicle body coordinate system based on the position of the tilt pin P7 in the vehicle body coordinate system, the tilt angle η, and the bucket length L4. In addition, the bucket position specification unit 212 can specify a position of a freely-selected point on the edge by specifying a distance from the center point of the edge to the freely-selected point on the edge, and by calculating a position that is offset from the position of the center point of the edge by the distance from the center point of the edge to the freely-selected point in a direction of the tilt angle η. For example, the bucket position specification unit 212 can specify positions of both ends of the edge by calculating positions that are offset from the position of the center point of the edge by ½ the length of the edge in a width direction in positive and negative directions of the tilt angle η.

The boom relative angle α, the arm relative angle β, the bucket relative angle γ, and the tilt angle η are respectively specified by the detection value of the boom cylinder stroke sensor 1561, the detection value of the arm cylinder stroke sensor 1571, the detection value of the bucket cylinder stroke sensor 1581, and the detection value of the tilt cylinder stroke sensor 1631. The bucket position specification unit 212 converts the position of the edge of the bucket 155 in the vehicle body coordinate system into a position in the site coordinate system based on the position of the swing body 130 in the site coordinate system, the azimuth direction where the swing body 130 faces, and the posture of the swing body 130.

Incidentally, the detection of the boom relative angle α, the arm relative angle β, the bucket relative angle γ, and the tilt angle η is not limited to being performed by the cylinder stroke sensors and may be performed by angle sensors or IMUs.

<<Operation of Control Device 190>>

FIG. 6 is a flowchart showing operation of the control device 190 according to the first embodiment. FIG. 7 is a view showing a relationship between the target design surface and a point on the edge in the automatic tilt control.

When the operator of the work machine 100 starts operation of the work machine 100, the control device 190 executes the following controls at predetermined control cycles.

The operation amount acquisition unit 215 acquires an operation amount related to the boom 151, an operation amount related to the arm 152, an operation amount related to the bucket 155, an operation amount related to tilt, and an operation amount related to the swing of the swing body 130 from the operation device 172 (step S1). The detection value acquisition unit 211 acquires information detected by each of the position and azimuth direction detector 131, the tilt detector 132, the boom cylinder stroke sensor 1561, the arm cylinder stroke sensor 1571, the bucket cylinder stroke sensor 1581, and the tilt cylinder stroke sensor 1631 (step S2).

The bucket position specification unit 212 calculates the boom relative angle α, the arm relative angle β, the bucket relative angle γ, and the tilt angle η from a stroke length of each of the hydraulic cylinders (step S3). In addition, the bucket position specification unit 212 calculates positions of five points in the site coordinate system that divide the edge of the bucket 155 into four equal segments, based on the detection values acquired in step S2, the angles calculated in step S3, and the known length parameters of the work equipment 150 (step S4). Hereinafter, the five points on the edge of the bucket 155 are referred to as a point p1, a point p2, a point p3, a point p4, and a point p5 in order from the left end of the edge. In other words, the point p1 is a point at the left end of the edge, the point p5 is a point at the right end of the edge, and the point p3 is the center point of the edge.

Incidentally, when angles are directly detected using angle sensors or IMUs, step S3 may be omitted.

The target plane determination unit 213 reads out the design surface data from the storage 250, and calculates a distance between each of the points p1 to p5 and the target design surface (step S5). In step S5, the target plane determination unit 213 calculates a distance between each point of the points p1 to p5 and a triangular polygon facing the each point in a direction extending from the each point in the vertical direction (Zg-axis direction). In the example shown in FIG. 7, the target plane determination unit 213 calculates distances L11 to L13 between the points p1 to p3 and a triangular polygon t1 and distances L14 and L15 between the points p4 and p5 and a triangular polygon t2. When a position of the edge of the bucket 155 is specified in the site coordinate system, the design surface data based on the site coordinate system is used. When a position of the edge of the bucket 155 is specified in the vehicle body coordinate system, design surface data based on the vehicle body coordinate system may be used. For example, the design surface data based on the vehicle body coordinate system may be obtained by converting the design surface data based on the site coordinate system into data in the vehicle body coordinate system based on the detection values of the position and azimuth direction detector 131 and of the tilt detector 132.

Next, the target plane determination unit 213 specifies a triangular polygon related to the shortest distance, and determines a plane passing through the triangular polygon, as the target plane g1 (step S6). In the example shown in FIG. 7, since the distance L13 between the point p3 and the triangular polygon t1 is the shortest distance among the distances L11 to L15, the target plane determination unit 213 determines a plane passing through the triangular polygon t1, as a target plane g1.

The distance calculation unit 214 calculates a distance L21 between the point p1 and the target plane g1 and a distance L22 between the point p5 and the target plane g1 based on the positions of the points p1 and p5 at the both ends of the edge calculated in step S4 and the target plane g1 determined in step S6 (step S7). In step S7, the target plane determination unit 213 calculates the distances L21 and L22 between the points p1 and p5 and the target plane g1 in a normal direction of the target plane g1.

Next, the tilt control unit 217 determines whether or not there is a tilt operation input by the operator, based on the operation amounts acquired in step S1 (step S8). For example, when an absolute value of the tilt operation amount is less than a predetermined value, the tilt control unit 217 determines that there is no operation input. When there is no tilt operation (step S8: NO), the tilt control unit 217 determines whether or not at least one of the distance L21 between the point p1 and the target plane g1 and the distance L22 between the point p5 and the target plane g1 specified in step S7 is less than a tilt control distance th (step S9).

When at least one of the distance L21 and the distance L22 is less than the tilt control distance th (step S9: YES), the tilt control unit 217 calculates a difference between the distance L21 and the distance L22 calculated in step S7 (step S10). Next, the tilt control unit 217 calculates a tilt control amount based on the difference between the distance L21 and the distance L22 (distance difference) (step S11).

FIG. 8 is a view showing an example of a tilt function showing a relationship between a distance difference of the bucket and a target value of a tilt angular speed according to the first embodiment. The distance difference of the bucket shown in FIG. 8 is obtained by subtracting the distance L22 from the distance L21 shown in FIG. 7, and the counterclockwise angular speed in FIG. 7 is positive.

In step S11, the tilt control unit 217 substitutes the distance difference into the tilt function determined in advance as shown in FIG. 8 to determine a target value of a tilt angular speed. The tilt function is a function for obtaining a target value of the tilt angular speed based on the distance difference of the bucket 155. In the tilt function, the target value of the tilt angular speed increases monotonically with the distance difference of the bucket 155. In addition, in the tilt function, an upper limit value and a lower limit value of the tilt angular speed are determined, and when an absolute value of the distance difference is more than a predetermined value, the target value of the tilt angular speed is constant. In addition, a dead zone (hysteresis) is set in the tilt function, and when the distance difference is within the dead zone near zero, the target value of the tilt angular speed is zero. In other words, when the distance difference is within the dead zone near zero, the rotation of the bucket 155 around the tilt axis X4 is stopped. Then, the tilt control unit 217 determines a tilt control amount based on the determined target value of the tilt angular speed.

Since the dead zone is provided in the tilt function, the tilt control of the bucket 155 can be prevented from repeating overshooting and overcorrection. Accordingly, when the tilt angle η of the bucket 155 is controlled by the automatic tilt control, rattling can be prevented from occurring on an excavation surface. In addition, the dead zone is specified by an allowable error amount for a target construction surface, so that it is possible to prevent rattling of the excavation surface while suppressing an excavation error of the target construction surface within the allowable error amount.

Incidentally, when a tilt operation is performed (step S8: YES) or when both the distance L21 and the distance L22 are the tilt control distance th or more (step S9: NO), the tilt control unit 217 does not calculate the tilt control amount.

Then, the output unit 218 outputs a control signal to each actuator based on each operation amount related to the work equipment 150 and the tilt control amount calculated by the tilt control unit 217 (step S12). When the automatic tilt control is being executed, the tilt cylinder 163 is driven according to the signal generated by the tilt control unit 217. When the automatic tilt control is not executed, the tilt cylinder 163 is driven according to a signal based on the operator operation amount.

As described above, the control device 190 according to the first embodiment calculates the first distance L21 that is a distance between the first bucket point p1 on the bucket 155 and the target design surface and the second distance L22 that is a distance between the second bucket point p5 which is a point on the bucket 155 and the target design surface, and compares the first distance L21 and the second distance L22 to calculate a tilt control amount to rotate the bucket 155 around the tilt axis X4. Accordingly, the control device 190 can automatically control the work equipment 150 such that the bucket 155 moves along the target design surface.

Incidentally, in the first embodiment, the first bucket point p1 and the second bucket point p5 are the both ends of the edge of the bucket 155, but the present invention is not limited to this configuration. For example, in another embodiment, the point p2 and the point p4 may be set as the first bucket point and the second bucket point. In addition, in another embodiment, the control device 190 may calculate a tilt control amount based on the tilt angle η of the bucket 155. On the other hand, the excavation error for the target construction surface can be easily managed by using the difference between the distances at the both ends of the edge of the bucket 155.

For example, when the control device 190 calculates a tilt control amount based on the tilt angle η of the bucket 155, the excavation error generated by an error of the tilt angle η changes depending on the length of the edge of the bucket 155. On the other hand, as in the first embodiment, when a tilt control amount is calculated based on the difference between the distances of the both ends of the bucket 155 to the target plane, the excavation error does not change depending on the length of the edge of the bucket 155.

In addition, in the first embodiment, when the difference between the first distance L21 and the second distance L22 is within the dead zone, the control device 190 stops rotation around the tilt axis X4. In other words, in the first embodiment, when the angle formed by the edge of the bucket 155 and the target design surface is a predetermined threshold value or less, the control device 190 stops rotation around the tilt axis X4. Accordingly, the tilt control of the bucket 155 can be prevented from repeating overshooting and overcorrection. In addition, the dead zone is specified by the allowable error amount for the target construction surface, so that it is possible to prevent rattling of the excavation surface while suppressing the excavation error of the target construction surface within the allowable error amount.

The embodiments have been described above in detail with reference to the drawings; however, the specific configurations are not limited to the above-described configurations, and various design changes and the like can be made. In other words, in another embodiment, the order of the above-described processes may be appropriately changed. In addition, some of the processes may be executed in parallel.

The control device 190 according to the above-described embodiments may be formed of a single computer, or the configurations of the control device 190 may be divided into a plurality of computers, and the plurality of computers may cooperate with each other to function as a control system. At this time, some computers forming the control device 190 may be mounted inside the work machine 100 and the other computers may be provided outside the work machine 100.

The control device 190 according to the above-described embodiments obtains the distances L11 to L15 and the distances L21 and L22 based on the reference shown in FIG. 7, but the present invention is not limited to this configuration. For example, the control device 190 according to another embodiment may obtain the distances L11 to L15 as distances with respect to a normal direction of a triangular polygon, or may obtain the distances L11 to L15 as distances with respect to a direction orthogonal to the edge of the bucket 155. In addition, the control device 190 according to another embodiment may obtain the distances L21 and L22 as distances in the vertical direction or may obtain the distances L21 and L22 as distances in the direction orthogonal to the edge of the bucket 155. In addition, for example, the triangular polygons t1 and t2 may be selected from a line of intersection between the target design surface and a tilt movement plane passing through the edge of the bucket 155 and being orthogonal to the tilt axis X4.

The control device 190 according to the above-described embodiment compares the first distance L21 and the second distance L22 to calculate a tilt control amount to rotate the bucket 155 around the tilt axis X4, but the present invention is not limited to this configuration. For example, when one of the first distance L21 and the second distance L22 is less than the tilt control distance th, the control device 190 according to another embodiment may calculate a tilt control amount based on the other of the first distance L21 and the second distance L22 at that time. For example, when the first distance L21 is less than the tilt control distance th, the control device 190 may calculate a tilt control amount based on the magnitude of the second distance L22 at that time. In addition, for example, when the distance of either of the first distance L21 or the second distance L22 is a predetermined value or more, the control device 190 may prevent rotation around the tilt axis X4. In other words, the control device 190 calculates a tilt control amount based on at least a larger value of the first distance L21 and the second distance L22.

The control device 190 according to the above-described embodiments always enables the automatic tilt control, but the present invention is not limited to this configuration. The operation device 172 according to another embodiment may include a switch that allows for switching between enabling and disabling of the automatic tilt control. In this case, the control device 190 may determine whether or not to perform the automatic tilt control based on a state of the switch. In other words, in a case where the switch is ON, when there is no tilt operation input (step S8: NO) and the distance between the edge of the bucket 155 and the target plane g1 is less than the tilt control distance th (step S9: YES), the control device 190 performs the automatic tilt control. On the other hand, in a case where the switch is OFF, even when there is no tilt operation input and the distance between the edge of the bucket 155 and the target plane g1 is less than the tilt control distance th, the control device 190 does not perform the automatic tilt control. As long as the switch can be operated by the operator, the switch may be provided as a function of a monitor (not shown) or may be disposed on an operation lever or the like.

According to the disclosure, the control system for the work machine is capable of automatically controlling the work equipment such that the tilt bucket moves along the target design surface.

Claims

1. A control system for a work machine including a boom rotatable around a boom axis, an arm rotatable around an arm axis parallel to the boom axis, and a bucket rotatable around a bucket axis parallel to the arm axis and rotatable around a tilt axis orthogonal to the bucket axis, the system comprising: a distance calculation unit configured to calculate a first distance that is a distance between a first bucket point being a point on the bucket and a target design surface representing a target shape of an excavation target, anda second distance that is a distance between the target design surface and a second bucket point, the second bucket point being a point on the bucket on a straight line passing through the first bucket point and being parallel to an edge of the bucket; anda tilt control unit configured to calculate a tilt control amount to rotate the bucket around the tilt axis based on at least a larger value of the first distance and the second distance.

2. The control system for a work machine according to claim 1, wherein when a difference between the first distance and the second distance is a predetermined threshold value or less, the tilt control unit prevents rotation of the bucket around the tilt axis.

3. The control system for a work machine according to claim 2, wherein the first bucket point and the second bucket point are points at both ends of the edge of the bucket, andthe threshold value is a value equal to or less than an allowable height error for the target design surface.

4. The control system for a work machine according to claim 1, wherein the tilt control unit calculates the tilt control amount related to an angular speed corresponding to a difference between the first distance and the second distance.

5. The control system for a work machine according to claim 1, wherein the target design surface is formed of a plurality of polygonal surfaces, andwhen the target design surface includes two or more polygonal surfaces facing the bucket, the distance calculation unit specifies a plane passing through one of the two or more polygonal surfaces,calculates a distance between the plane and the first bucket point as the first distance, andcalculates a distance between the plane and the second bucket point as the second distance.

6. The control system for a work machine according to claim 5, wherein the plane passes through a polygonal surface having a shortest distance to the bucket among the two or more polygonal surfaces.

7. A control system for a work machine including a boom rotatable around a boom axis, an arm rotatable around an arm axis parallel to the boom axis, and a bucket rotatable around a bucket axis parallel to the arm axis and rotatable around a tilt axis orthogonal to the bucket axis, the system comprising: a tilt control unit configured to calculate a tilt control amount to rotate the bucket around the tilt axis such that an edge of the bucket and a target design surface representing a target shape of an excavation target approach each other in a parallel state, andstop rotation of the bucket around the tilt axis when an angle formed by the edge of the bucket and the target design surface representing the target shape of the excavation target is a predetermined threshold value or less.

8. A work machine comprising: a boom configured to be rotatable around a boom axis;an arm configured to be rotatable around an arm axis parallel to the boom axis;a bucket configured to be rotatable around a bucket axis parallel to the arm axis and to be rotatable around a tilt axis orthogonal to the bucket axis; andthe control system for a work machine according to claim 1.

9. A method for controlling a work machine including a boom rotatable around a boom axis, an arm rotatable around an arm axis parallel to the boom axis, and a bucket rotatable around a bucket axis parallel to the arm axis and rotatable around a tilt axis orthogonal to the bucket axis, the method comprising the steps of: calculating a first distance that is a distance between a first bucket point being a point on the bucket and a target design surface representing a target shape of an excavation target;calculating a second distance that is a distance between the target design surface and a second bucket point, the second bucket point being a point on the bucket on a straight line passing through the first bucket point and being parallel to an edge of the bucket; andcalculating a tilt control amount to rotate the bucket around the tilt axis based on at least a larger value of the first distance and the second distance.

10. A work machine comprising: a boom configured to be rotatable around a boom axis;an arm configured to be rotatable around an arm axis parallel to the boom axis;a bucket configured to be rotatable around a bucket axis parallel to the arm axis and to be rotatable around a tilt axis orthogonal to the bucket axis; andthe control system for a work machine according to claim 7.