Control systems and methods for heavy equipment

Heavy equipment includes a main body, a drivetrain, a work implement, and a control system. The drivetrain includes a first and second actuator providing speed and direction movement of the heavy equipment. The work implement includes a third and fourth actuator providing position and orientation of the work implement. The control system includes first and second main interfaces and first and second auxiliary interfaces, to allows an operator to simultaneously control the drivetrain and the work implement. The first main interface is operated by a first hand of the operator, and the control system operates the third actuator responsive to a signal from the first main interface. The first auxiliary interface is integrated with the first main interface, and operates simultaneously with the first main interface by a finger of the first hand. The control system operates the first actuator responsive to a signal from the first auxiliary interface.

BACKGROUND

The present disclosure relates generally to the field of control systems, such as control systems for operating heavy equipment.

Heavy equipment is typically operated by way of both hand controllers, such as steering wheels, levers, stick shifts, and the like, and foot controllers, such as pedals for clutch, throttle and brake operation. As such, by way of both the hand and foot controllers, the operator may drive the heavy equipment and also operate a work implement of the heavy equipment, such as a drill, bucket, breaker, or other implement.

SUMMARY

One embodiment relates to heavy equipment that includes a main body, a drivetrain, a work implement, and a control system. The drivetrain includes a first actuator and a second actuator, and is coupled to the main body and configured to facilitate movement of the heavy equipment. The first and second actuators of the drivetrain provide both speed and direction for the movement of the heavy equipment. The work implement includes a third actuator and a fourth actuator, and is coupled to the main body. The third and fourth actuators provide the position and orientation of the work implement. The control system for the heavy equipment includes first and second main interfaces as well as first and second auxiliary interfaces, where the control system allows an operator to simultaneously control the drivetrain and the work implement. The first main interface is configured for operation by a first hand of the operator, and the control system operates the third actuator at least partially as a function of a signal provided by the first main interface. The first auxiliary interface is integrated with the first main interface, and is configured for simultaneous operation with the first main interface by a finger of the first hand. The control system operates the first actuator at least partially as a function of a signal provided by the first auxiliary interface. The second main interface is configured for operation by a second hand of the operator, and the control system operates the fourth actuator at least partially as a function of a signal provided by the second main interface. The second auxiliary interface is integrated with the second main interface, and is configured for simultaneous operation with the second main interface by a finger of the second hand. The control system operates the second actuator at least partially as a function of a signal provided by the second auxiliary interface.

Another embodiment relates to heavy equipment configured for mining, excavation, and construction applications. The heavy equipment includes a main body, a drivetrain, a work implement, and a control system. The main body is configured to support an operator of the heavy equipment. The drivetrain is coupled to the main body and configured to facilitate movement of the heavy equipment. In addition, the drivetrain includes a first actuator, a first track, a second actuator, and a second track, where the first actuator is coupled to the first track and the second track is coupled to the second track. The first and second actuators drive the respective tracks. The work implement is coupled to the main body, and includes a third actuator and a fourth actuator. The third and fourth actuators provide the position and orientation of the work implement. The control system for the heavy equipment includes a first joystick, a first switch, a second joystick, and a second switch, and is coupled to the main body, allowing the operator to simultaneously control the drivetrain and the work implement from the main body. The control system operates the third actuator at least partially as a function of a signal provided by the first joystick. The first switch is integrated with the first joystick, and the control system operates the first track by way of the first actuator at least partially as a function of a signal provided by the first switch. The signal provided by the first switch is independent from the signal provided by the first joystick. The control system operates the fourth actuator at least partially as a function of a signal provided by the second joystick. The second switch is integrated with the second joystick, and the control system operates the second track by way of the second actuator at least partially as a function of a signal provided by the second switch. The signal provided by the second switch is independent from the signal provided by the second joystick. The first and second switches may each be used to change the rotation speed and direction of the respective track, together controlling the speed and direction of the heavy equipment.

Yet another embodiment relates to a control system for operating two or more sub-systems. The control system includes a first joystick, a first auxiliary interface, a second joystick, and a second auxiliary interface. The first joystick is moveable in at least four directions, and provides a first signal that is at least partially a function of the direction in which the first joystick is moved. The first auxiliary interface is integrated with and coupled to a side of the first joystick. Further, the first auxiliary interface is operable in at least two positions, and provides a second signal that is at least partially a function of the position in which the first auxiliary interface is operated. The second joystick is moveable in at least four directions, and provides a third signal that is at least partially a function of the direction in which the second joystick is moved. The second auxiliary interface is integrated with and coupled to a side of the second joystick. Further, the second auxiliary interface is operable in at least two positions, and provides a fourth signal that is at least partially a function of the position in which the second auxiliary interface is operated. The first and third signals together at least partially control the operation of a work-implement sub-system, and the second and fourth signals together at least partially control the operation of a propel sub-system. The work-implement and propel sub-systems are simultaneously controllable independent of each other by way of the respective joysticks and auxiliary interfaces.

DETAILED DESCRIPTION

Referring toFIG. 1, heavy equipment in the form of an electric rope shovel110includes a main body112, a drivetrain114(e.g., motor, gearbox, rotating shafts, tracks, wheels, etc.), and a work implement116(e.g., shovel, blade, forks, bucket, saw, vibratory plate and associated guiding structure). The electric rope shovel110is designed to excavate overburden and ore during mining applications. However, althoughFIG. 1shows the heavy equipment in the form of the electric rope shovel110, in other embodiments a broad range of heavy equipment and other systems benefit from the innovations described herein, including power shovels, small excavators, draglines, backhoes, mobile drills, bulldozers, forklifts, cranes, and other heavy equipment for construction, mining, or other applications.

The main body112of the electric rope shovel110includes an operator cab118and components associated with powering the drivetrain114and the work implement116. An operator (see, e.g., operator214as shown inFIG. 2) may sit in the cab118and control the drivetrain114and the work implement116by way of a control system (see, e.g., control system210as shown inFIG. 2). In other embodiments, the operator may be positioned in a control center that is disconnected from the heavy equipment, and/or the heavy equipment may be partially or fully automated. In some embodiments, the components associated with powering the drivetrain114and the work implement116include generator sets (e.g., diesel generators), electric drives (e.g., inverters), slew and hoist motors and associated gearing, and other components.

According to an exemplary embodiment, components of the drivetrain114of the electric rope shovel110include tracks120,122that facilitate movement of the electric rope shovel110(i.e., propel). The rate of rotation of the tracks120,122controls the speed of the electric rope shovel110, and a difference in relative rotation rates of the tracks120,122turns the electric rope shovel110. For example, when the right track120rotates in a forward direction and the left track122rotates in a rearward direction, the electric rope shovel110turns left. Alternatively, if both tracks120,122rotate in the forward direction, but the left track122rotates faster than the right track120, then the electric rope shovel110turns right. In other embodiments, heavy equipment uses motive elements other than tracks, such as wheels, pontoons, etc.

According to an exemplary embodiment, the electric rope shovel110further includes the work implement116, which includes an articulated arm124formed from a boom126coupled to a stick128(e.g., dipper). The stick128may translate and/or rotate relative to the boom126. A bucket130is coupled to the stick128and is designed to collect the overburden and ore. Translational movement of the stick128relative the boom126, such as by way of a hydraulic cylinder, retract ropes (e.g., metal cables), rack and pinion, and/or other systems, facilitates crowding of the bucket130. Hoist ropes132controllably raise and lower the bucket130. Slew motors (see generally actuator338as shown inFIG. 3) coupled to the main body112allow for rotation of the main body112(e.g., swing) and corresponding movement of the bucket130relative to the tracks120,122.

Referring now toFIG. 2, a control system210includes a support structure212(e.g., seat, stool, platform, etc.) for an operator214, and one or more main interface216,218(e.g., controller, joystick, mouse). In some embodiments, the control system210is attached to a cab and/or a main body of heavy equipment (see, e.g., cab118, main body112of electric rope shovel110as shown inFIG. 1). In other contemplated embodiments, the control system210is remotely located relative to the system or systems controlled thereby and in electromagnetic communication therewith.

According to an exemplary embodiment, the main interfaces216,218are accessible to the operator214when the operator214is supported by the support structure212. In some such embodiments, the support structure212further includes arm rests220, and the main interfaces216,218are coupled to the arm rests220. In other such embodiments, the main interfaces216,218are coupled to a console, a table, or another structure proximate to the support structure212. The position of the main interfaces216,218relative to the operator214and relative to each other may be adjustable or fixed. According to an exemplary embodiment, the main interfaces216,218are located at generally the same vertical height as each other, relative to the operator214when the operator214is supported by the support structure212(e.g., seated). Further, the main interfaces216,218are located at about the same distance from the operator214when the operator214is supported by the support structure212.

According to an exemplary embodiment, one of the main interfaces216,218is configured for operation by a left hand222of the operator214and the other of the main interfaces216,218is configured for operation by the right hand224of the operator214, allowing the operator to control one or more sub-systems. Auxiliary interfaces226,228(e.g., dials, buttons, switches, slides, touch screens, toggles, etc.) integrated with (e.g., attached to, extending from, connected to, contacting) the main interfaces216,218may be ergonomically positioned on the main interfaces216,218, allowing the operator214control of one or more additional sub-systems with a finger (e.g., index finger, thumb, both middle and ring fingers together, etc.) of the hands222,224, while handling the main interfaces216,218.

In some embodiments, use of the main interfaces216,218in combination with the auxiliary interfaces226,228allows the operator214to control sub-systems without use of foot pedals. Applicants believe that the hand-operated main and auxiliary interfaces216,218,226,228allow for improved performance because of fine motor skills associated with hands and fingers. In addition, Applicants believe that the presently described hand-operated main and auxiliary interfaces216,218,226,228, in place of foot pedals, allow the operator214greater comfort with the support structure212. For example, the operator214is free to adjust leg positions while operating the hand-operated main and auxiliary interfaces216,218,226,228. Accordingly, without impacting operation of the control system210in some embodiments, no foot pedals are included for the control of certain sub-systems, such as a drivetrain sub-system (see, e.g., drivetrain114as shown inFIG. 1). In other embodiments, foot pedals are used for direct or alternate control of some sub-systems.

Referring toFIG. 3, heavy equipment310includes a control system312, a drivetrain314, and a work implement316. The control system312includes two or more main interfaces318,320, and each main interface318,320includes at least one auxiliary interface322,324integrated therewith. According to an exemplary embodiment, each main interface318,320is configured to provide a signal326,328(e.g., comment, instruction, direction) that is a function of movement of the respective main interface in forward, rearward, left, or right directions, or combinations thereof. Each auxiliary interface322,324provides a signal330,332independent of the signal326,328provided by the respective main interface318,320. According to an exemplary embodiment, the auxiliary interfaces322,324are configured to provide signals330,332that are a function of movement in forward and rearward directions.

According to an exemplary embodiment, the drivetrain314includes a first actuator334(e.g., electric motor, internal combustion engine, hydraulic motor, linear actuator, hydraulic cylinder, solenoid) and a second actuator336. The work implement316includes a third actuator338and a fourth actuator340. According to such an embodiment, the signal326provided by the first auxiliary322interface controls the first actuator334and the signal328provided by the second auxiliary interface324controls the second main actuator336. The signal330provided by the first main interface318controls the third actuator338, and the signal332provided by the second main interface320controls the fourth actuator340.

In contemplated embodiments, the signal330provided by the first main interface318further controls a fifth actuator342, and the signal provided by the second main interface320further controls a sixth actuator344. In at least one such contemplated embodiment, the first and second actuators334,336include hydraulic motors that drive respective tracks of heavy equipment (see, e.g., tracks120,122as shown inFIG. 1), the third actuator338includes an electric slew motor for rotating a main body (see, e.g., main body112as shown inFIG. 1) of the heavy equipment relative to the tracks, the fourth actuator344includes a hydraulic cylinder for rotating a boom (see, e.g., boom126as shown inFIG. 1) relative to the main body, the fifth actuator342includes a hydraulic cylinder for moving (e.g., rotating, translating) a stick (see, e.g., stick128as shown inFIG. 1) relative to the boom, and the sixth actuator344includes a hydraulic cylinder for rotating a bucket (see, e.g., bucket130as shown inFIG. 1) relative to the stick. In other embodiments, the main and auxiliary interfaces318,320,322,324provide signals to control other actuators, other numbers of actuators, other motions of actuators, etc.

Still referring toFIG. 3, the heavy equipment310further includes a first controller346and a second controller348(e.g., computer, drive, inverter, valve assembly, etc.), where each controller346,348is configured to operate independently from the other. According to an exemplary embodiment, the first controller346is associated with the work implement316and the second controller348is associated with the drivetrain314. As such, signals330,332from the main interfaces318,320are provided to the first controller346and signals326,328from the auxiliary interfaces322,324are provided to the second controller348.

In some embodiments, the controllers346,348include inverters or drives associated with each interface and configured to control a flow of electricity (e.g., frequency, amplitude, current, voltage, power, etc.) to respective electric-motor actuators. The inverters or drives may be integrated with the main and auxiliary interfaces318,320,322,324of the control system312or separately located on the heavy equipment310. In other contemplated embodiments, the controllers346,348include valves (e.g., system of solenoid-operated cartridge valves) configured to control the flow of pressurized hydraulic fluid to hydraulic actuators.

Referring now toFIGS. 4-6, joysticks410,412each include auxiliary interfaces414,416,418,420,422(FIG. 5). One joystick410is particularly configured for operation by a left hand of an operator (see, e.g., left hand222and operator214as shown inFIG. 2) and the other joystick412is particularly configured for operation by a right hand of the operator (see, e.g., right hand224as shown inFIG. 2). In some such embodiments, the joysticks410,412mirror each other, having curvature and auxiliary interfaces414,416,418,420,422symmetrically arranged about a center plane defined between the joysticks410,412. In other embodiments, the joysticks include different contours and/or auxiliary interfaces.

According to an exemplary embodiment each joystick410,412may be rotated in at least four directions, such as forward, rearward, left, and right. In some embodiments, each joystick410,412has a ball or gimbaled joint, and is configured to freely rotate in at least two degrees of freedom about the ball or gimbaled joint (i.e., moveable in a full 360-degrees). In still other embodiments, one or more of the joysticks410,412is limited to a single degree of freedom, such as forward or rearward rotation about a fixed axis.

According to an exemplary embodiment, operation of each joystick410,412is used to generate a signal (e.g., electric signal, mechanical motion, flow of fluid, optical signal, etc.) that is at least partially a function of the position, movement, velocity, rotation, translation, loading, and/or another state of the respective joystick410,412. According to such an exemplary embodiment, electro-mechanical components, such as switches, potentiometers, variable resistors, sensors (e.g., load cells, accelerometers) and/or other components are coupled to the joysticks410,412and provide the signal, which is responsive to the state of the joystick410,412.

The signal may be an analog or digital signal. In some embodiments, an analog signal is converted to a digital signal, filtered, and conditioned by an associated computer. In other embodiments, a mechanical or hydraulic linkage transmits the signal. In still other embodiments, other methods are used to convert the state of the joystick to a corresponding signal. According to an exemplary embodiment, signals provided by the joysticks410,412are used to control a work implement of heavy equipment, such as the movement of a bucket relative to the ground (see, e.g., bucket130as shown inFIG. 1). In other embodiments, the signals provided by the first and second joysticks control other features or operations of a sub-system associated with the heavy equipment (e.g., dipper crowding, plow angle, adjustment breaker orientation control, etc.).

Still referring toFIGS. 4-6, the joysticks410,412further include the auxiliary interfaces414,416. In some embodiments, the auxiliary interfaces414,416,418,420,422for each joystick include a switch414,416(e.g., rocker switch). According to an exemplary embodiment, each switch414,416is lengthwise oriented along a longitudinal axis of the corresponding joystick410,412, and moves (e.g., slides, rocks, rotates) relative to the joystick410,412. In some such embodiments, the switches414,416are located on a rearward side of the joysticks410,412, angled inward toward each other, and ergonomically configured for control by thumbs of the operator. According to an exemplary embodiment, the switch414on the left joystick410is used to control a left track of heavy equipment (e.g., propel function), and the switch416on the right joystick412is used to control a right track.

In some embodiments the switches414,416are rocker switches, and the motion of each switch414,416is limited to rotation about a single axis (i.e., two directions), and provides a control signal (e.g., related to speed, direction, torque, etc.) that is proportional to the direction and amount of rotation about the axis. As such the rotation direction of the respective track corresponds to the direction that the switch414,416is rotated, and the rotational speed of the respective track corresponds to the degree to which the switch414,416is rotated. The control signal may be linearly related, exponentially related, or otherwise related to the movement. In other contemplated embodiments, one or more rocker switches may rotate in more than two directions, to control multiple parameters (e.g. direction and speed) of one or more sub-systems by way of a single switch, for example.

Referring toFIG. 7, another joystick (see also joysticks410,412as shown inFIGS. 4-6) has auxiliary interfaces512including buttons514,516,518,520,522. In other contemplated embodiments, one or more of the buttons514,516,518,520,522may instead be finger grooves or contours of the joystick. The motion of each button514,516,518,520,522is limited to translation in a single degree of freedom, such as in and out of the joystick. In some embodiments, one or more of the buttons514,516,518,520,522provides a control signal that is proportional to the number of times the button514,516,518,520,522is operated. In some embodiments, the auxiliary interface512may include two or more such buttons514,516,518on the same joystick, where one button514is associated with a forward direction and another button516is associated with a rearward direction of motive elements of heavy equipment, or where one button514is associated with an increase in rate, torque, load, etc. and the other button516is associated with a decrease for a work implement. Other buttons518,520,522may reset the signal to an initial setting, provide a stop signal, provide instructions to maintain current settings, release overburden from a bucket into a haul truck, or provide other instructions.

In some embodiments, one or more of the buttons514,516,518,520,522provides a signal, which is proportional to the length of time that the button514,516,518,520,522is held down, the length of time since the button514,516,518,520,522was initially pressed, the force applied to the button514,516,518,520,522, and/or another interaction parameter. In one such contemplated embodiment, upon pressing of a first button, a control computer provides a ramping of speed, load, rate of rotation, etc., which is slowly increased until a second button is pressed, or until the first button is pressed a second time.

In still other embodiments, other control modes are contemplated where the buttons514,516,518,520,522may otherwise be used to control tracks, articulated arm segments, or other sub-systems of heavy equipment. In some such embodiments, the operator may be simultaneously providing a first signal via movement of the joystick with a right or left hand, providing a second signal via the buttons514,516,518with the corresponding thumb, and providing a third signal via the button522with the corresponding index finger. In other embodiments, the joysticks further or otherwise include additional auxiliary interfaces, such as triggers, buttons, or toggles on the tops and/or sides of the joysticks.