System and method for operating a machine

A system and method for operating a machine is disclosed. The system may include an input device configured to select from a plurality of modes of operation for the machine, the plurality of modes of operation comprising a manual mode, a remote mode, and an autonomous mode. The system may further include a controller coupled to the machine, the controller configured to place the machine in the selected mode of operation based on an input at the input device. The system may further include a transmitter configured to transmit a heartbeat signal. The system may further include a receiver configured to receive an acknowledgment signal from a remote system in response to the transmitted heartbeat signal.

TECHNICAL FIELD

The present disclosure relates generally to operating machines, and more particularly to a system and method for operating a machine in a remote or an autonomous mode.

BACKGROUND

Mining and large scale excavating operations may require fleets of machines to transport excavated material (e.g., dirt, rocks, gravel, etc.) from an area of excavation to a secondary location. For such an operation to be productive and profitable, the fleet of machines must be efficiently operated. One way to efficiently operate a fleet of machines is to reduce the number of operators required to operate the fleet by, for example, operating machines in a remote and/or an autonomous mode.

A system for operating a machine in an autonomous mode is disclosed in U.S. Pat. No. 7,277,784 (the '784 patent), issued to Weiss. The '784 patent discloses operating a manned harvester and an unmanned transport machine. The unmanned transport machine contains a control unit connected to a receiving unit that is configured to receive position data from the harvester. The control unit operates the transport machine based on the position data from the harvester and, for example, drives the transport machine relative to the position of the harvester.

Although the '784 patent may increase the efficiency of a fleet of machines by reducing the number of required operators, the '784 patent may not be suitable for operating multiple machines in an excavating operation. In particular, the '784 patent may be incapable of allowing a machine the ability to operate in a remote and/or an autonomous mode while performing multiple different operations with little supervision.

The disclosed system and method is directed towards improving existing systems and methods for operating machines.

SUMMARY

In one aspect, the present disclosure is directed to a system for operating a machine. The system may include an input device configured to select from a plurality of modes of operation for the machine, the plurality of modes of operation comprising a manual mode, a remote mode, and an autonomous mode. The system may further include a controller coupled to the machine, the controller configured to place the machine in the selected mode of operation based on an input at the input device. The system may further include a transmitter configured to transmit a heartbeat signal. The system may further include a receiver configured to receive the transmitted heartbeat signal.

In another aspect, the present disclosure is directed to a method for operating a machine. The method may include selecting a single mode of operation for the machine from a plurality of modes of operation for the machine, the plurality of modes of operation comprising a manual mode, a remote mode, and an autonomous mode. The method may further include placing the machine in the selected mode of operation. The method may further include transmitting a heartbeat signal.

In another aspect, the present disclosure is directed to a machine configured to operate in a plurality of modes. The machine may include a controller configured to place the machine in a selected mode of operation based on an input at an input device, the selected mode of operation being one of a manual mode, a remote mode, and an autonomous mode. The machine may further include a communication device configured to receive or send a first signal.

DETAILED DESCRIPTION

FIG. 1illustrates an exemplary machine100. Although machine100is illustrated as a dozer, machine100may be any type of machine that performs some type of operation associated with an industry such as mining, construction, farming, transportation, etc. For example, machine100may be an earth moving machine such as, for example, an excavator, a loader, a backhoe, a dozer, a motor grader, and the like.

Machine100may comprise a wireless communication device102, a GPS antenna103, and a controller104. Wireless communication device102may comprise one or more wireless devices configured to send and/or receive wireless communications to and/or from remote locations. For example, machine100may use wireless communication device102to wirelessly exchange information with other machines, and/or a remote site such as, for example, a control center (not shown). Controller104may comprise a system of one or more electronic control modules configured to identify one or more functions and/or operations of machine100that may be adjusted and controlled by a remote control and/or autonomously.

GPS antenna103may embody any position monitoring device suitable for gathering three-dimensional (e.g., x, y, and z) coordinate information associated with machine100or an implement or tool associated therewith. According to one embodiment, GPS antenna103may be located on a work implement (e.g. a blade) of machine100in order to monitor the precise location of the work implement. Such a configuration may enable machine100and/or an off-board terrain design system to determine, among other things, the progress and productivity of earth-moving operations and other tasks performed by machine100and work implements associated therewith. According to another embodiment, GPS antenna103may be located on the cab (or another location on machine100). Such a configuration may be ideal for keeping GPS antenna103protected from certain ground-level hazards. However, such configuration may require additional sensors to be connected to the work implement, in order to precisely determine the position of work implement. It is contemplated that machine100may include multiple GPS antennae103in order to provide a redundancy, in the event that one or more of the other GPS antennae103should malfunction or otherwise become inoperable.

In order to perform the desired operations of machine100, controller104may include one or more computer mapping systems105. The computer mapping system(s)105may be comprised of tables, graphs, and/or equations. The computer mapping system(s)105may relate to desired actuator speed or force, associated flow rates and pressures, valve element positions associated with movement of hydraulic cylinders, acceleration, velocity, braking, steering, and/or desired and current position and orientation of machine100. It is contemplated that the computer mapping system(s)105may be comprised of additional information required to perform the autonomous and/or remote operation of machine100. It is further contemplated that an operator of machine100may modify these mapping system(s) and/or select specific maps from available relationship maps stored in memory. In one example, the maps may additionally or alternatively be automatically selectable based on modes of machine operation. In yet another example, the computer mapping system(s)105may be continuously updated with geographical and topographical information of the working environment via wireless communication device102, and/or any other suitable communication device. Alternatively or additionally, the computer mapping system(s)105may be continuously updated by controller104associated with machine100. For example, GPS antenna103of machine100monitors the position of the blade during operation of machine100. This information may be fed into controller104, which may continuously and/or periodically update the computer mapping system(s)105.

One skilled in the art will appreciate that controller104may include additional and/or different components than those listed above. For example, controller104may include one or more other components or subsystems such as, for example, power supply circuitry, signal conditioning circuitry, solenoid driver circuitry, and/or any other suitable circuitry for aiding in the control of one or more systems of machine100.

Illustrated inFIG. 2is an exemplary embodiment where a plurality of machines100A,100B,100C,100D, and100E, collectively referred to herein as machines100A-100E, work together to perform an operation in a work environment200consistent with the disclosed embodiments and their equivalents. AlthoughFIG. 2illustrates a specific number and type of machines (i.e., five of machines100) working together autonomously or being controlled remotely, it is contemplated that any number and/or types of machines may work together autonomously or be controlled remotely. Additionally, although work environment200illustrates an above-ground mining environment, it is contemplated that work environment200may be representative of other working environments such as, for example, a construction environment, a farming environment, a below-ground mining environment, etc.

As illustrated inFIG. 2, machines100A-100E may work together autonomously to remove overburden that is covering a desired material. It is contemplated that the desired material may be any type of material such as, for example, a fossil fuel. In one embodiment, to remove the overburden, machines100A-100E may autonomously load the overburden at a first location. Machines100A-100E may then autonomously travel to a second location to dump the overburden. After machines100A-100E dump the overburden, machines100A-100E may then autonomously return to the first location to load more overburden for transport.

In order to accomplish the autonomous operations, controllers104of machines100A-100E may be preprogrammed and continuously updated with information such as, for example, geographical and topographical information of the worksite, and the position and orientation of other machines at the worksite. Respective controllers104of machines100A-100E may then use the preprogrammed and continuously updated information to assist in the operations of machines100A-100E, independent of an operator to obtain the desired topology of the site.

In another embodiment, to remove the overburden, machines100A-100E may be controlled remotely by an operator. As an example, as machines100A-100E operate autonomously, machine100C may have removed all of the overburden from its surroundings. In this example, an operator may, via remote control, stop the autonomous mode of machine100C, and move machine100C to a desired third location where overburden is required to be moved. Once machine100C is at the desired third location, the operator may then place the machine back into autonomous mode. Machine100C may then autonomously upload the terrain data base and the desired site plan and then proceed to load overburden from its surrounding location, and transport and dump the overburden at a desired location. Machine100C may then autonomously return to the third location and repeat the overburden removal process. It is contemplated that an operator may remotely operate one of machines100A-100E through the entire process of removing overburden while the other machines operate autonomously.

In one embodiment, while machine100operates in an autonomous mode, a wireless signal (i.e., a heartbeat signal) may be sent from/to machine100. The heartbeat signal may originate from the machine at the worksite, and communicate with a remote location such as, for example, a remote control device operated by an operator, or a remote management site. The heartbeat signal may be used as a way to monitor and/or stop the operations of machine100. As an example, if at any time machine100stops exchanging the heartbeat signal, machine100may come to a controlled stop and place itself in a safe mode. It is contemplated that machine100will not enter an autonomous mode until the heartbeat signal is acknowledged. It is further contemplated that a remote operator may have the ability to start and/or stop the heartbeat acknowledgement and response at any time, thus controlling when machine100may operate in an autonomous mode.

In another embodiment, while machine100operates in an autonomous mode, machine100may transmit a heartbeat signal to a computer system at a remote management site. The heartbeat signal may communicate to the computer system the status and operations that machine100is performing. If, based on the received heartbeat signal, the computer system at the remote management site determines that machine100is performing unauthorized operations, the computer system may send a signal to machine100, the signal forcing machine100to end all operations and place its self in a safe mode. It is contemplated that the computer system at the remote management site may be able to monitor several of machines100while they operate in autonomous mode.

As an example, to remove overburden from worksite200, machines100A-100E may autonomously load the overburden at a first location, and then travel to a second location to dump the overburden. While machines100A-100E are autonomously loading and transporting the overburden, each of machines100A-100E may be transmitting a heartbeat signal to a computer system at a remote management site, each of the heartbeat signals communicating to the computer system the operations of machines100A-100E, respectively. Additionally, while transporting a load to a dump site, machine100A may veer of course, and if not corrected by the on board machine controller, the computer system at the remote management site may receive, via a communication device, the heartbeat signal indicating that machine100A has veered of course on its way to the dump site. In response to the received heartbeat signal, the computer system at the management site may send a signal to machine100A, the signal forcing machine100A to end all operations and place itself in a safe mode.

INDUSTRIAL APPLICABILITY

The disclosed system and method for operating machines may increase the efficiency of work environment operations by reducing the number of operators required to operate a fleet of machines. The disclosed system and method for operating machines may reduce the number of operators required to operate a fleet of machines by allowing the machines to be operated in a remote and/or an autonomous mode.

FIG. 3shows a flowchart300illustrating a method for placing machine100in a manual, remote, or autonomous mode consistent with the disclosed embodiments and their equivalents. For remote/autonomous operation, a remote operator301auses a radio control console301bto select a manual, remote, or autonomous mode for machine100(Step302). For manual operation, a manual operator303switches off remote/autonomous operation (Step304) via, for example, a selector switch on the console in the machine cab. If the operator selects a manual mode of operation for machine100, the remote and automated controls at machine100will automatically be switched off (Step304), and machine100will enter a manual mode operation (Step306).

If the operator selects remote or autonomous mode for machine100, machine100may perform a self-test (Step308). Machine100may self-test components such as, for example, hydraulic controls, communication links, etc. As an example, machine100may initiate a self-test command to move a hydraulically controlled implement coupled to machine100. Machine100may then use sensors to verify that the implement did indeed move corresponding to the command. In one embodiment, the sensors may be pressure sensors that correspond to the movement of the hydraulically controlled implement. If machine100identifies a component that fails a self-test command (Step310, No), machine100may run diagnostics to locate the source of the failure (Step312). For example, after machine100initiates a self-test command to move a hydraulically controlled implement coupled to machine100, a pressure sensor associated with the implement may indicate that the implement did not move, or that the implement did not move as commanded. Machine100via controller104may use information indicative of the pressure sensor results to identify that the implement command failed the self-test.

Machine100may then transmit the diagnostic results to an operator at the remote location (Step314). In one embodiment, controller104may store the diagnostic results in an internal memory for later use. After machine100transmits the diagnostic results, machine100may enter a safe mode (Step316). It is contemplated that machine100may enter the safe mode even if machine100cannot run a diagnostic test, or if machine100cannot transmit the diagnostic results. As an example, if the error identified in the self-test is associated with wireless communication device102, machine100may not be able to transmit the results of the diagnostic self-test. In this example, machine100may still enter the safe mode, even though machine100was unable to transmit the results of the diagnostic self-test to an operator. In one embodiment, the safe mode may be machine100shutting down. If machine100passes the self-test (Step310, Yes), machine100may then determine which mode of operation the operator selected (Step318). If the operator selected the remote mode, machine100would enter the remote mode (Step320). If the operator selected the autonomous mode, machine100would begin to enter the autonomous mode as described inFIG. 5(Step322).

FIG. 4shows a flowchart400illustrating a method for operating machine100in a remote mode consistent with the disclosed embodiments and their equivalents. For example, after machine100enters the remote mode, machine100may upload a terrain database to a memory in controller104(Step402). The terrain database may include information indicative of a current terrain of a work environment, and a desired terrain of the work environment. As an example, a worksite may consist of a fossil fuel (e.g., coal), covered by one or more layers of overburden. In order to reach the fossil fuel, the layers of overburden must be removed. That is, in order to arrive at the desired terrain, e.g., the fossil fuel, the current terrain, e.g., the layers of overburden covering the fossil fuel, must be removed.

Information indicative of the current terrain of the worksite may be updated automatically in a memory of controller104via wireless communication device102. As an example, controller104may communicate with GPS satellites via GPS satellite antenna103so that controller104may be continuously updated to the geographical and topographical information of the active worksite. As another example, controller104may communicate via wireless communication device102with a manager control station that is being continuously updated to the geographical and topographical information of the worksite. The manager control station may, via wireless communication device102, continuously update controller104to the current geographical and topographical information of the worksite. It is contemplated that the desired terrain of the work environment may also be stored in a memory of controller104and updated automatically from the manager control station via wireless communication device102. It is further contemplated that the current position and orientation of machine100and other machines at the worksite may be continuously updated in controller104via wireless communication device102. It is also contemplated that the machine will update the geographical and topological information in controller104of machine100as the terrain is modified by machine100.

After machine100is updated with the current and desired terrain geography and topography of the worksite, an operator may use a remote control to position machine100to where overburden is desired to be removed (Step404). Once the operator has positioned machine100, the operator may use the remote control device to remove overburden from the worksite by starting a cut of the terrain (Step406). That is, the operator via a remote control may control machine100to load the blade or other implement of machine100to remove (or “cut”) the top layers of overburden that covers (Step407), for example, a fossil fuel or another resource that is desired to be removed from the worksite. While machine100is being used to remove the top layers of overburden from the worksite, machine100may monitor the current level of the terrain and compare the current level of the terrain with a threshold design level stored in a design database408b(Step408). If the blade depth is not at the desired design level (Step408: No), machine100may be instructed to continue to load up the blade (Step409) either until the blade is full (Step413a) or until the design level has been reached.

If, after loading the blade, the blade is at the threshold design level (Step408: Yes), the cut command may be terminated (Step410) and the cut may be executed to remove overburden to the current blade level. While cutting, machine100may detect when the blade is full (Step413a). If the blade is not full (Step413a: No), and machine100is not at the end of the cut, as designed (Step413b: No), machine100may be configured to load the blade (Step407). If the blade is full (Step413a: Yes) or if the blade is not full (Step413a: No) but machine100is at the end of the designed cut, (Step413b: Yes), machine100may carry the load to the dump area (Step414) and dump the load (Step416). If the load is completely dumped (Step418), machine100may return to the start of the cut sequence (Step420) by positioning the remote control tractor at or near the location of a desired cut (Step404).

FIG. 5shows a flowchart500illustrating a method for operating machine100in an autonomous mode consistent with the disclosed embodiments and their equivalents. For example, after machine100has passed the self-test, and before the machine100enters an autonomous mode, machine100may upload a terrain database to a memory in controller104(Step502). Again, the terrain database may include information indicative of a current terrain of a work environment, and a desired terrain of the work environment. The uploading and updating of the terrain database may follow the same process as described in the embodiment ofFIG. 4.

After machine100is updated with the current and desired terrain geography and topography of the worksite, machine controller104may plan the work cycle and position machine100to where overburden is desired to be removed (Step504).

According to certain exemplary embodiments, if the machine is operating consistent with certain threshold operating parameters machine100may periodically perform a heartbeat status check process (Step505). As shown in the “key” ofFIG. 5, the heartbeat status check process commences with transmission of a status signal (e.g., a “heartbeat” signal) by machine100(Step505a) to the remote control console or an autonomous monitoring system associated with machine100. The status signal may include general machine status information, as well as project or task progress information. The remote control console, the autonomous monitoring system, or any other off-board analysis system may evaluate the status and progress of machine100from the remote location (Step505b). Based on the analysis, the remote control console, the autonomous monitoring system, or the other off-board analysis system transmits either an authorization signal that allows machine100to continue autonomous operation or a “stop” command, which causes machine100to shut down autonomous operation of machine100(Step505c).

For example, if machine100is not operating in a manner consistent with one or more threshold operating parameters, remote control console, the autonomous monitoring system, or the other off-board analysis system may be configured to generate a “stop” command. If, on the other hand, machine100is operating in a manner consistent with one or more threshold operating parameters, the remote control console, the autonomous monitoring system, or the other off-board analysis system may be configured to generate an authorization signal that allows machine100to continue autonomous operation.

Accordingly, while machine controller104positions machine100(as in Step504), machine100may perform the heartbeat status check process (Step505) and, assuming the status check process passes, machine100will be allowed to continue operation. It is contemplated that the heartbeat status check process (as in Step505) may be performed at regular time intervals or during particular critical points during autonomous operation. In any case, if machine100is not operating consistent with threshold parameters, machine100will be shut down.

Once machine100is positioned at the desired location, the controller104may place machine100in autonomous mode (Step506). Once machine100is placed in autonomous mode, machine100may autonomously begin the cutting process by loading an implement (e.g., blade) of machine100(Step508). While machine is cutting/loading the implement, machine100may perform the heartbeat status check process (Step505).

While machine100is being used to remove the top layers of terrain from the worksite, machine100may monitor the current level of the terrain and compare the current level of the terrain with a threshold design level stored in a design database512a(Step512). If the blade depth is not at the desired design level (Step512: No), machine100may be instructed to continue to load up the blade (Step513) either until the blade is full (Step515a) or until the design level has been reached.

If, after loading the blade, the blade is at the threshold design level (Step512: Yes), machine100may autonomously cut the terrain to the design level (Step514). While machine is cutting the terrain, machine100may perform the heartbeat status check process (Step505). While cutting, machine100may detect when the blade is full (Step515a). If the blade is not full (Step515a: No), and machine100is not at the end of the cut, as designed (Step515b: No), machine100may be configured to load the blade (Step508). If the blade is full (Step515a: Yes) or if the blade is not full (Step4515a: No) but machine100is at the end of the designed cut, (Step515b: Yes), machine100may carry the load to the dump area (Step516) and dump the load (Step518). During each of steps516and518, machine100may perform the heartbeat status check process (Step505). If the load is completely dumped (Step520: Yes), machine100determine if the desired terrain design profile has been met (Step522) by comparing the current level of the terrain with a threshold design level stored in a design database512a(as in Step512). If the desired terrain profile has not been met (Step522: No)), machine100may autonomous return to the start of the cycle (Step524) by positioning machine100at or near the location of a desired cut (Step504). If, on the other hand, the desired terrain design has been met (Step522: Yes), machine100may park itself in safe made (Step526).

Although the steps in flowcharts300,400, and500are described in relation to a particular work environment and particular machines, it is contemplated that the steps in flowcharts300,400, and500may be applicable to any working environment and/or any machine. Furthermore, the examples described in flowcharts300,400, and500are not intended to be limiting. For example, those familiar with the art will appreciate that the steps in flowcharts300,400, and500may consist of fewer or additional steps. In addition, it is contemplated that the steps in flowcharts300,400, and500may be performed non-consecutively.