Construction machine sensor system

A system for mounting a sensor on a construction machine is described. The system includes a sensor having a bottom interface and a base for mounting the sensor on a construction machine. The base includes a top interface for rotatably interlocking with the bottom interface of the sensor. The rotatably interlocking of the base with the bottom interface of the sensor causes one or more terminals of the bottom interface of the sensor to communicatively couple to corresponding terminals of the top interface of the base.

BACKGROUND

The present invention relates generally to a sensor system, and more particularly to a sensor system for mounting on a construction machine to withstand the harsh conditions of a construction site.

A construction machine typically relies on a number of different sensors to perform tasks in a safe and efficient manner. However, during operation, the harsh vibrations and movements of the construction machine make implementation of those sensors difficult. Conventional sensors are implemented on a construction machine by separately mounting each sensor on the construction machine and running a cable from each sensor to a control unit. Such conventional sensors are tedious to configure and do not allow for the rapid addition or substitution of sensors of different types.

BRIEF SUMMARY OF THE INVENTION

In accordance with one or more embodiments, a system for mounting a sensor on a construction machine is described. The system includes a sensor having a bottom interface and a base for mounting the sensor on a construction machine. The base includes a top interface for rotatably interlocking with the bottom interface of the sensor. The rotatably interlocking of the base with the bottom interface of the sensor causes one or more terminals of the bottom interface of the sensor to communicatively couple to corresponding terminals of the top interface of the base.

In one embodiment, the bottom interface of the sensor includes a recessed center portion having a notch and the top interface of the base includes a protruding center portion having an extended portion. The extended portion of the protruding center portion of the top interface of the base is configured to fit into the notch of the recessed center portion of the bottom interface of the sensor when the top interface of the base is rotatably interlocked with the bottom interface of the sensor.

In one embodiment, the sensor includes a top interface for rotatably interlocking with a bottom interface of another sensor. The rotatably interlocking of the top interface of the sensor with the bottom interface of the other sensor causes one or more terminals of the top interface of the sensor to communicatively couple to corresponding terminals of the bottom interface of the other sensor. The top interface of the sensor may include a protruding center portion having an extended portion and the bottom interface of the other sensor may include a recessed center portion having a notch. The extended portion of the protruding center portion of the top interface of the sensor is configured to fit into the notch of the recessed center portion of the bottom interface of the other sensor when the top interface of the sensor is rotatably interlocked with the bottom interface of the other sensor.

In one embodiment, the one or more terminals of the bottom interface of the sensor includes one or more spring loaded terminals. The one or more spring loaded terminals communicatively couple to the corresponding terminals of the top interface when the top interface of the base is rotatably interlocked with the bottom interface of the sensor.

In one embodiment, the top interface of the base is for rotatably interlocking with the bottom interface of the sensor via a bayonet mount configuration.

In one embodiment, the sensor includes a global positioning system sensor.

In one embodiment, a sensor includes a bottom interface. The bottom interface includes coupling elements and a set of terminals. The coupling elements are for rotatably interlocking the sensor with a base mounted on a construction machine. The rotatably interlocking of the sensor with the base causes each terminal of the set of terminals of the bottom interface of the sensor to communicatively couple to corresponding terminals of the base.

In one embodiment, a method for rotatably interlocking a sensor with a base is described. A bottom interface of a sensor is positioned on a top interface of a base. The bottom interface of the sensor is rotated relative to the top interface of the base to rotatably interlock the sensor with the base. The rotating of the bottom interface of the sensor relative to the top interface of the base causing one or more terminals of the bottom interface of the sensor to communicatively couple to corresponding terminals of the top interface of the base.

DETAILED DESCRIPTION

FIG. 1shows a high-level overview of a construction site100, in accordance with one or more embodiments. Construction site100includes construction machines104-A,104-B, and104-C (collectively referred to as construction machines104). Construction machines104may include any machine or device used in construction, such as, e.g., an excavator, a bulldozer, a dump truck, a tractor, and/or any other type of construction equipment. Construction machines104work together to perform a construction task, such as, e.g., digging a trench, dispersing material over a target area, etc. Construction machines104may include any number of construction machines of a same or different type. While the embodiments discussed herein are described with respect to construction machines104operating in construction site100, the invention is not so limited. Embodiments of the invention may be applied for any type of machine or vehicle operating in any environment. For example, embodiments of the invention may be applied for an agricultural machine, a mining machine, etc.

Each construction machine104-A,104-B, and104-C includes a sensor system106-A,106-B, and106-C (collectively referred to as sensor systems106), respectively. Each sensor system106-A,106-B, and106-C comprises one or more sensors108-A,108-B, and108-C (collectively referred to as sensors108) and a base110-A,110-B, and110-C (collectively referred to as bases110), respectively. Sensors108may include any number of sensors for generating data of, e.g., construction machine104or construction site100to facilitate the performance of the construction task. Exemplary sensors of the one or more sensors include a global positioning system (GPS) antenna/sensor, a reflective optical 360 degree prim unit for determining a position, a millimeter laser receiver for determining a height (in conjunction with a remote stationary laser), a gyroscope, an accelerometer, a temperature sensor, a moisture sensor, or any suitable sensor or combinations of sensors. Sensors108are mounted on construction machines104via bases110.

Sensor system106-A,106-B, and106-C are communicatively coupled to a control unit108-A,108-B, and108-C (collectively referred to as control units108), respectively. Control units108may include memory (e.g., random access memory) and storage (e.g., persistent storage) operatively coupled to one or more processors (not shown). The storage may store computer program instructions which may be loaded into the memory and executed by the processor to perform operations, e.g., for processing sensor data from sensor systems106. In one embodiment, the computer program instructions may be for providing feedback or guidance to an operator of construction machine104to optimize performance of the construction task. Accordingly, control units108may include a display device (not shown) and/or a user interface (not shown).

Communications network102facilitates communications between construction machines104(or any other computing device) via control units108to perform the construction task. Communications network102may include any suitable network, such as, e.g., a wired or wireless computer network, the Internet, a telephone network, a cellular network, a satellite network, etc. In one embodiment, communications network104is a mesh network where each construction machine104acts as a node to cooperate in the distribution of data. In this embodiment, each node is communicatively coupled with all other nodes within communication range.

Construction machines104operating in construction environment100generate considerable amounts of vibration and experience other extreme conditions. Advantageously, sensors108are mounted on construction machines104via bases110in a manner to withstand the harsh vibrations and extreme conditions of construction environment100, while allowing sensors108to be added, removed, and/or substituted in sensor system106with minimal reconfiguration of control units108.

FIG. 2Ashows an illustrative sensor system200in an interlocked state, in accordance with one or more embodiments. In one embodiment, sensor system200may be sensor system106inFIG. 1. Sensor system200includes a top sensor202-A, an intermediate sensor202-B, and a bottom sensor202-C (collectively referred to as sensors202) coupled to base214for mounting on a construction machine (e.g., construction machine104inFIG. 1). Sensors202and base214are configured to rotatably (or pivotably) interlock with each other to form a sensor system (e.g., sensor system106ofFIG. 1). Accordingly, top sensor202-A is configured to rotatably interlock with intermediate sensor202-B, intermediate sensor202-B is configured to rotatably interlock with bottom sensor202-C, and bottom sensor202-C is configured to rotatably interlock with base214.

FIG. 2Bshows an exploded bottom perspective view of sensor system200in a non-interlocked state andFIG. 2Cshows an exploded top perspective view of sensor system200in a non-interlocked state, in accordance with one or more embodiments. Intermediate sensor202-B, bottom sensor202-C, and base214each include a top interface206-A,206-B, and206-C (collectively referred to as top interface206), respectively, as shown inFIG. 2C. Top sensor202-A, intermediate sensor202-B, and bottom sensor202-C each include a bottom interface204-A,204-B, and204-C (collectively referred to as bottom interface204), respectively, as shown inFIG. 2B. Top interface206is configured to rotatably interlock with bottom interface208by any suitable means to thereby rotatably interlock, e.g., top sensor202-A with intermediate sensor202-B, intermediate sensor202-B with bottom sensor202-C, and bottom sensor202-C with base214. Base214is configured to mount sensors202on a construction machine (not shown). For example, securing element212, such as, e.g., a pole clamp, may secure base214to pole210, which is mounted on the construction machine. Base214may include a vibration isolator pad216for absorbing vibrations (e.g., from a construction machine) and reducing the impact of the vibrations on sensors202.

In one embodiment, one or more sensors202may include one or more status indicators208-A and208-B, such as, e.g., light-emitting diodes (LEDs), display devices, etc. Indicators208-A and208-B indicate the status (e.g., power, network connectivity, etc.) of their sensors202-A and202-C respectively.

FIG. 3Ashows an exemplary top interface206andFIG. 3Bshows an exemplary bottom interface204, in accordance with one embodiment. While interfaces206and204are shown and described as being a top interface and a bottom interface respectively, it should be understood that top interface206may alternatively be a bottom interface (of sensors202) and bottom interface208may alternatively be a top interface (sensors202and/or base214).

Male coupling elements302of top interface206are configured to couple with corresponding female coupling elements310of bottom interface204to allow top interface206to rotatably interlock with bottom interface204. In one embodiment, male coupling elements302are radial pins and female coupling elements310are slotted receptors to form a bayonet mount configuration, as shown and described in more detail with respect toFIGS. 3C and 3D. It should be understood that male coupling elements302and female coupling elements310may be any suitable coupling element for rotatably interlocking top interface206and bottom interface204, and are not limited to the bayonet mount configuration shown and described herein.

FIG. 3Cshows a side view of male coupling elements302ofFIG. 3A, in accordance with one embodiment. Male coupling element302is shown as a radial pin having a head316and a tail318. Head316has a diameter larger than the diameter of tail318.

FIG. 3Dshows a top down view of female coupling elements310ofFIG. 3B, in accordance with one embodiment. Female coupling element310is shown as a slotted receptor having receptor320and slot322. Receptor320has a diameter larger than the diameter of head316of male coupling element302to allow head316to be inserted into receptor320. Slot322has a width324larger than the diameter of tail318but smaller than the diameter of head316of male coupling element302to allow top interface206to rotatably interlock with bottom interface204.

Referring back toFIGS. 3A and 3B, top interface206includes a protruding center portion304comprising an extended portion306and a set of receiving terminals308. Bottom interface204includes a recessed center portion312comprising a notch314and a set of connecting terminals316. Each sensor202and base214has a plurality of different connections. In one embodiment, the plurality of different connections comprises a connection for power, a connection for ground, a connection for controller area network (CAN) high, a connection for CAN low, a connection for communication between sensors202, and four connections for other data (e.g., Ethernet connections). Accordingly, each connection has a respective receiving terminal308and its corresponding connecting terminal316. The receiving terminals308of the top interface206of the base214communicatively couple to a control unit (e.g., control unit112ofFIG. 1) to transmit and/or receive data from sensors202. While the set of receiving terminals308and their corresponding connecting terminals316are shown inFIG. 3Aas having nine connections (i.e., nine receiving terminals308and nine corresponding connecting terminals316), it should be understood that the set of receiving terminals308and their corresponding set of connecting terminals316may comprise any number of terminals. The terminals in the set of connecting terminals316may be of any suitable length to allow connecting terminals316to communicatively couple to corresponding terminals of the set of receiving terminals308when top interface206rotatably interlocks with bottom interface204. In one embodiment, connecting terminals316are spring loaded connecting terminals316and receiving terminals308are flush with a top surface of protruding center portion304to facilitate rotation of top interface206with bottom interface204and thereby communicatively couple connecting terminals316and receiving terminals308without damage.

With reference toFIGS. 3A-3D, in operation, to rotatably interlock top interface206with bottom interface204, top interface206is positioned on (i.e., pressed against) bottom interface204such that head316of male couplers302is inserted into receptor320of female coupling elements310and protruding center portion304is inserted into recessed center portion312. In particular, protruding center portion304is inserted into recessed center portion312such that extended portion306fits within notch314to thereby ensure top interface206is correctly oriented with bottom interface204and receiving terminals308communicatively couple with their corresponding connecting terminals316. The insertion of protruding center portion304into recessed center portion312causes spring loaded connecting terminals316to retract to a surface of protruding center portion304.

Top interface206is then rotated relative to bottom interface204such that tail318is rotated into slot322. While top interface206is rotated in the clockwise direction into slot322inFIGS. 3A-3D, it should be understood that top interface206may be rotated in the counter-clockwise direction into slot322in a different configuration of female coupling elements310. The larger diameter of head316relative to the smaller width324of slot322causes top interface206to rotatably interlock with bottom interface204. The rotation of top interface206relative to bottom interface204causes spring loaded connecting terminals316to couple with corresponding ones of the receiving terminals308. The degree and direction of rotation of top interface206relative to bottom interface204to rotatably interlock top interface206with bottom interface204is based on length326of slot322. In one embodiment, the top interface206is rotated 7.2 degrees clockwise relative to bottom interface204. Top interface206includes raised portions328to create a firm fit with bottom interface204when interlocked. In one embodiment, slot322of female coupling elements310include a vertical spring loaded bullet head plunger (not shown) to securely interlock male coupling elements302and female coupling elements310and thereby prevent unintentional unlocking, e.g., due to vibrations.

Advantageously, sensors202are mounted on construction machines via bases214in a manner to withstand the harsh vibrations and extreme conditions of a construction environment, while allowing sensors108to be added, removed, and/or substituted in sensor system106with minimal reconfiguration of control units108. In particular, base214comprises vibration isolator pad216for reducing the effect of vibrations on sensors202. Raised portions328of top interface206create interference flex pressure with bottom interface204to further reduce the effects of shock and vibration. Spring loaded connecting terminals316are able to extend and compress under vibration and shock to main connection.

In one embodiment, a single connection associated with a receiving terminal308and its corresponding connecting terminals316is for communicating, e.g., between sensors202(FIGS. 2A and 2B), control unit112(FIG. 1), etc. For example, a frequency and/or amplitude of a voltage on the particular terminal may be modulated for bi-directional communication between sensors202, control unit112, etc. In one embodiment, an upper sensor (e.g., sensor202-A) may send a request for information to a lower sensor below it (e.g., sensor202-B or202-C) and the lower sensor will respond with its information (e.g., sensor type, location of the sensor relative to the other sensors, etc.).

FIG. 4shows a flow diagram of a method400for rotatably interlocking a sensor with a base for mounting the sensor on a construction machine, in accordance with one or more embodiments. Method400will be described with reference to sensor system200ofFIGS. 2A-2B and 3A-3D.

At step402, a bottom interface204-C of a sensor202-C is positioned on a top interface206-C of a base214. For example, the sensor202-C may be a GPS sensor, a gyroscope, an accelerometer, a temperature sensor, a moisture sensor, or any suitable sensor or combinations of sensors. In one embodiment, head316of male couplers302of top interface206-C of base214is inserted into receptor320of female coupling elements310of bottom interface204-C of sensor202-C and protruding center portion304of top interface206-C of base214is inserted into recessed center portion312of bottom interface204-C of sensor202-C. In one embodiment, protruding center portion304of top interface206-C is inserted into recessed center portion312of bottom interface204-C such that extended portion306of protruding center portion304fits within notch314of recessed center portion312. The extended portion306and notch314ensure that sensor202-C is correctly oriented with base214, to thereby ensure that connecting terminals316of bottom interface204-C of sensor202-C communicatively couples with their corresponding receiving terminals308of top interface206-C of base214.

At step404, the bottom interface204-C of the sensor202-C is rotated relative to the top interface206-C of the base214to rotatably interlock the sensor202-C with the base214. In particular, tail318of coupling element302of top interface206-C of the base214is rotated into slot322of coupling element310of bottom interface204-C of the sensor202-C. The larger diameter of head316relative to the smaller width324of slot322causes top interface206to rotatably interlock with bottom interface204. The rotatably interlocking of the base214with the sensor202-C causes one or more terminals316of the bottom interface204-C of the sensor202-C to communicatively couple to corresponding terminals308of the top interface206-C of the base314. The degree and direction of rotation of top interface206-C relative to bottom interface204-C to rotatably interlock sensor202-C with base214is based on length326of slot322and the length of notch314of recessed portion312(receiving extended portion306of protruding center portion304). In one embodiment, the top interface206-C is rotated 7.2 degrees clockwise relative to bottom interface204-C.

In one embodiment, sensor202-C may include a top interface206-B, which may be positioned on a bottom interface204-B of another sensor202-B. The top interface206-B of sensor202-C may be rotated relative to bottom interface204-B of the other sensor202-B to rotatably interlock sensors202-B and202-C. The rotation of the top interface206-B of sensor202-C relative to bottom interface204-B of the other sensor202-B causes one or more terminals of the top interface206-B of sensor202-C to communicatively couple to corresponding terminals of bottom interface204-B of the other sensor202-B.