Method of controlling machines at a worksite

A method of controlling machines for performing operations at a worksite is disclosed. The method includes receiving pre-construction terrain data, design terrain data, and resource data and then defining a plurality of constraints based on the data. Operations of the machines are simulated based on the data. The method includes estimating process variables associated with the operations and defining and scheduling tasks to be performed by the machines. The method includes collecting real time data from the worksite and updating the estimated process variables and the scheduled tasks of the machines based on the collected real time data. Instructions are then provided to the machines for executing the tasks.

TECHNICAL FIELD

The present disclosure relates to machines and more particularly to a method of controlling operations of the machines at a worksite.

BACKGROUND

Generally, earthmoving work at a worksite is carried out based on a planned profile prepared prior to execution of the construction work at the worksite. Further, during the execution of the construction work, a site profile of the construction work may be generated by monitoring the worksite using un-manned aerial systems. In conventional method, the site profile is subtracted from the planned profile to analyze the construction work at the worksite. The planned profile may be prepared based on the amount of material to be transferred at the worksite, routes of the machine involved in the construction works and the distance to be travelled by the machine, which may not be helpful in anticipating desired cost, productivity, and a turn-around time associated with the construction work.

U.S. Patent Publication Number 2013/0035978, hereinafter referred to as '978 publication discloses a computer implemented route determination system. The computer implemented route determination system includes a route generator, a cost scenario generator, and a report generator. The route generator is configured to define a plurality of routes on which move a material between a construction site and a destination site of a plurality of possible destination sites. The cost scenario generator is configured to determine cost scenarios associated with the plurality of routes. The report generator is configured to generate a report which identifies the routes and the cost scenarios for the destination site. However, the '978 publication does not disclose a method of controlling construction work at the worksite.

SUMMARY OF THE DISCLOSURE

A method of controlling machines for performing operations at a worksite is disclosed. The method comprises receiving pre-construction terrain data, design terrain data, and resource data associated with the worksite. The method defines a plurality of constraints associated with the operations based on the data, simulates operations of the machines at the worksite based on the data, and estimates process variables associated with the operations. Real time data is then collected from the machines and process variables are updated. Then instructions are provided to the machines to execute the scheduled tasks.

DETAILED DESCRIPTION

Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or the like parts.FIG. 1is a diagrammatic view showing an exemplary worksite10. The worksite10may be a construction site and/or a mining site. The worksite10includes one or more machines. The machines12may include mining trucks, haul trucks, on-highway trucks, off-highway trucks, articulated trucks, and any other machines used for performing earth moving operations at the worksite10. The machines12may be deployed in the worksite10for performing one or more operations such as, transportation of material from one location to another location (i.e., hauling). The machines12also include loading machines, such as, conveyors, excavators, wheel loaders, track-type loaders, shovels, draglines, and any other machine used for performing excavation operation at the worksite10. The one or more machines also include scrapers, track-type tractors, compactors, and motor graders to perform additional work site operations including dumping, spreading, compacting, site maintenance and upkeep, grading, etc. Therefore, the machines12can perform operations such as loading, hauling, dumping, filling, cutting, excavating, spreading, compacting, grading etc.

The machines12deployed at the worksite10may be communicated to each other and various systems via a communication medium14. Examples of the communication medium14may include, but are not limited to, a Wide Area Network (WAN), a Local Area Network (LAN), an internet, an intranet, a cellular network, a satellite network, or any other known network for transmitting and receiving data. In various examples, the communication medium14may include a combination of two or more of the aforementioned networks and/or other types of networks known in the art. Further, the communication medium14may be implemented as a wired network, a wireless network, or a combination thereof. Further, data transmission may take place over the communication medium14with a network protocol such that the data transmission may be in an encrypted format or any other secure format, or in any of wide varieties of known manners. In one example, the one or more operations of the machines12are monitored using an unmanned aerial system (UAS)140(shown inFIG. 4). The UAS140may be controlled by a remote control unit (not shown). The unmanned aerial system collects data of the machines12deployed at the worksite10.

The machines12are connected to a control system16via the communication medium14and the unmanned aerial system. The control system16could be located on any of the machines12at the worksite10. The control system16is configured to perform earthmoving operations control and guidance. The control system16controls the one or more operations performed by the machines12at the worksite10. The machines12may include hardware components and/or software components that enable sending informational and operational control data between the machines12and the control system16, and between the machines12. Moreover, an operator of the machine12controls one or more operation tasks performed by the machine12using the hardware components and/or software components for manned and remote control operation. Completion of one or more operations at the worksite10includes a planning phase and an execution phase of the one or more operations.

The control system16is implemented in the planning phase and the execution phase. In planning phase, the one or more operations to be performed at the worksite10are planned by the control system16. In the execution phase, the planning performed at the planning phase may be modified by a site supervisor or work director, and is updated by the control system16. The hardware components and/or software components on board the machine may enhance task execution with additional application specific controls to improve operation. Constraints160may be weighted based on customer preferences inputted via a user interface module150. The user interface module150may be a terminal, tablet, smart phone, touch display, and computer that is connected to portions of the control system16as is known in the art. For instance, one customer may prioritize cost while another customer may prioritize time. The control system16is explained in detail along with the planning and execution phase with reference toFIG. 2.

Referring toFIG. 2, a schematic block diagram of the control system16is disclosed. The control system16is communicably coupled to various databases and the user interface module150. The control system16receives data from the databases and the user interface module150. The data received by the control system16includes a pre-construction terrain data100. The control system16receives the pre-construction terrain data100at a block18. The data is related to the worksite10. For example, the pre-construction terrain data100may be collected via a worksite survey. The pre-construction terrain data100may include two or three-dimensional surface and sub-surface data. The pre-construction terrain data100may be received from a database and/or the user interface module150connected to the control system16. The user interface module150may have the Graphical User Interphase (GUI) for enabling the operator interaction with the user interface module150.

FIG. 4is a graphical representation of three dimensional pre-construction terrain data100juxtaposed with three dimensional design terrain data110. The three dimensional pre-construction terrain data100and the three dimensional design terrain data110are hereinafter referred to as the pre-construction terrain data100and the design terrain data110, respectively. The pre-construction terrain data100may be collected via a worksite survey from the UAS140, satellite, or other aircraft. The difference between the pre-construction terrain data100and the design terrain data110defines a volume of material180to be moved at the worksite10.

The pre-construction terrain data100also includes material information. The material information include, but is not limited to, information related to soil at the worksite10, type of materials involved in the one or more operation, and a cost of materials involved in the one or more operation. In one example, the information related to the soil may include a proprietary soil data, a test methodology used to test soil, compaction of the soil, swell/shrink factors of the soil, and data from a public soil database. The pre-construction terrain data100may also include a location of the worksite10, off-site locations for source and waste material, and predicted or historical weather data of the worksite10. The pre-construction terrain data100can also include information regarding underground utilities, overhead utilities, structures, easements, and bodies of water.

At block19, the control system16receives the design terrain data110. The design terrain data110includes a three dimensional or two dimensional model of a design profile to be formed at the worksite10, list of one or more operations to be performed at the worksite10to accomplish the design profile, impacts of the one or more operations to be performed at the worksite10, schedule data (restrictions on hours of operation, and schedule deadlines and late completions cost penalties). In another aspect of the current disclosure, the design terrain data110could include a final road surface, a superstructure, footings, or any other build infrastructure to be included at the worksite10.

At a block20, the control system16receives resource data120. The resource data120may include information associated with the machines12. The resources data120could include the machines12or skilled labor130, the UAS140, or other robots. The resource data120may also include data regarding the cost of the skilled labor130and their associated skill level. The skilled labor130could include machine operators, laborers, inspectors, or surveyors. The resource data120may also include external materials that are added to the worksite10such as fill material, stabilizers, aggregate, etc.

The information associated with the machines12may include information of a fleet of the machines12available at the worksite10for performing the one or more operations. In one example, the information of the fleet of the machines12includes the number of machines12available at the worksite10and the type of the machines12available at the worksite10. The information associated with the fleet may be received from the user interface module150in communication with the control system16. In another example, the information associated with the fleet may be received from the database connected to the control system16.

The resource data120further includes resource performance data. The resource performance data may include productivity and efficiency data associated with each of the machines12available in the fleet. The resource performance data may be collected from a manufacturer performance handbook or a database. In another example, the resource performance data may be collected from multiple productivity field tests conducted for each of the machines12or from historical operational data taken from previous work sites. Examples of information included in the resource data120are fuel consumption, payload, productivity, travel speed, cycle time, pass matching (how many times it takes a load operation to fill a hauling machine), dig depth, machine geometry, machine transport costs, generated noise, etc.

The control system16is implemented in the planning phase of one or more operations. At the planning phase, the control system16simulates the one or more operations to be performed at the worksite10at a block22. In order to simulate the one or more operations, the control system16defines the constraints160associated with the worksite10. The constraints160are defined based on the pre-construction terrain data100, the design terrain data110, and the resource data120. In one example, the constraints160may include project budget, project schedule, and available resources (such as available machines12or skilled labor130).

Further, the control system16simulates the one or more operations performed by the machines12at the worksite10. A simulation is performed based on the pre-construction terrain data100, the design terrain data110, and the resource data120. In one example, the simulation may consider information such as machine specific data, accurate terrain information of the worksite10, and an order of the one or more operations of the machines12to be performed at the worksite10. The simulation may be performed regarding the operations of the machines12required to move the volume of material180. The order of the one or more operations may be defined using an earthwork planner as is known in the art, without limiting the scope of present disclosure.

At a block24, the control system16estimates process variables170associated with the one or more operations. The process variables170are estimated based on the simulation of the one or more operations and the plurality of constraints160. The control system16implements methods known in the art, such as linear and mixed integer linear programming, discrete event simulation, agent-based modeling, along with proprietary simulation techniques, for estimating the process variables170based on the constraints160. The process variables170include tasks to be performed by the machines12, the order in which they are to be performed, (i.e. task schedule), and the types and number of resources required to perform the tasks.

At the block24, the control system16schedules one or more tasks to be performed by the machines12at the worksite10. The one or more tasks are scheduled based on the simulation of the one or more operations. Moreover, information such as, but is not limited to, the task to be implemented at the worksite10, and a set of subsequent tasks to be performed. In one example, the simulation of the one or more operations generates a set of instructions for controlling the machines12deployed at the worksite10. In one example, additional tasks are received from the user interface module150. Tasks may be at an operational level (move to a location, perform a cut, dump at a location, establish a certain grade, etc.) or may be more detailed instructions for the machine12to execute (engine fueling to 40%, lift implement to a certain height, shift to a specific gear, follow a specific path, etc.).

The task schedule is a list or collection of tasks that is sorted in the order in which they are to be performed. The task schedule may include types of resources (such as machines) and a scheduled time for the task to be performed. The process variables170may also include the types of machines needed to perform the simulated operations at the worksite10. For example, an output of the simulation may indicate that three excavators, eight hauling units, two track-type tractors, two wheel-tractor scrapers, two motor graders, and forty units of skilled labor will be required to perform the required operations at the worksite10. The types of resource may also be broken down to specific types of model (i.e. eight 320 excavators, one each of D5k and D6N track-type tractors, etc.).

In the exemplary worksite10, the one or more operations may include cutting operation and filling operation. The control system16may simulate the cutting operation and the filling operation based on the pre-construction terrain data100and the resource data120. The control system16may receive the pre-construction terrain data100and the resource data120corresponding to the cutting operation and the filling operations from the databases and the user interface module150. Based on the simulation, the control system16estimates the process variables170and the schedule of one or more tasks. Further, the simulation also generates information required to coordinate the machines12such as the excavators, wheel loaders, the track-type loaders, and the shovels with the mining trucks, the haul trucks, the on-highway trucks for performing the cutting operation, and the filling operation.

The machines12deployed in the worksite10are enabled to determine the location of each other for completing the one or more operations. The machines12may be equipped with a location tracking device such as a GPS or GNSS device. An operator of the machine12may control the movement of the machine based on the determined locations. For instance, for completing the cutting operation and the filling operation, the truck communicates with digging machines to identify the GPS co-ordinates of the digging machines to determine the location of the digging machines. Further, the truck receives a new load and travels to a dump location via a hauling route.

The machines12may include hardware components and/or software components that determine and use locations of each other to coordinate operations and to control machine tasks. In another aspect of the current disclosure, the machine12may configured to be operated from a remote location by the operator. Control commands may be issued over communication medium14or any other suitable communication network as is known in the art. Further, the machine12may be configured to operate autonomously according to a set of instructions. The set of instructions may be located on a controller onboard the machine12, a neighboring machine12, or may be issued by the control system16over the communication medium14.

The control system16is also implemented at the execution phase of the one or more operations at the worksite10. During the execution phase, the control system16monitors a progress of the one or more operations at the worksite10. At a block26, the control system16collects real time data from the worksite10during the execution phase. The real time data collected from the worksite10may include, but is not limited to, an amount of material transferred at the worksite10, performance details of each of the machines12deployed at the worksite10, operator inputs, information on productivity of the skilled labor130, and data obtained from a worksite survey. The control system16may collect the real time data via the communication medium14. The real time data may be used to define a current terrain model124.

In one example, the control system16may collect data directly from the machines12deployed at the worksite10via the communication medium14. In another example, the machines12deployed at the worksite10may be communicated to multiple source systems (not shown) such as terrain management system and fleet management system. The source systems may collect the data of the machines12and store in a data warehouse (not shown). The data warehouse is in communication with the source systems. The control system16may collect the real time data of the machines12from the data warehouse. The control system16collects operator inputs via the user interface module150connected to the control system16. An operator of the machines12may be enabled to provide the real time data of the worksite10to the control system16using the GUI of the user interface module150.

Some of the real time data collected in the data warehouse may need preparation to be utilized by the simulation in the execution phase. Data preparation could include, but is not limited to; data cleansing to improve data accuracy and correct data discrepancies, data conversion to transform the real time data to be compatible in form and content with the original worksite and the resource data120and to provide improved site-specific data for the simulation in the execution phase. Data analytics and pre-simulation models may be used to cleanse and convert the real time data in the data warehouse.

In execution phase, the one or more operations at the worksite10are simulated by the control system16upon receiving the real time data, at the block22. The simulation of the one or more operations during the execution phase is performed based on the real time data received at the block26, the pre-construction terrain data100received at the block18, the design terrain data110received at the block19, and the resource data120received at the block20.

At a block28, the control system16updates the process variables170associated with the one or more operations estimated during the planning phase based on the real time data. The control system16updates the process variables170based on the simulation of the one or more operations at the execution phase. The updated process variables170may include, but is not limited to, a revised cost of the one or more operations, a revised time required for the one or more operations, and revised type and number of the machines12required for performing the one or more operations. The control system16also updates the identified and scheduled one or more tasks of the machines12based on the simulation of the one or more operations performed at the block26. The control system16also generates a progress report of the one or more operations performed at the worksite10based on the real time data and the simulation of the one or more operations. The control system16may also generate a three dimensional model of the worksite10based on the real time data received from the worksite10via the user interface module150. For example, if the machines12are deployed in a construction site, then the three dimensional model of the worksite10may be a built model of a building to be constructed at the construction site. The task and schedule updates generated by the simulation may be reviewed and modified by a site supervisor or work director and input using the user interface module150. These modifications are used as new input data for the off-board system to update the simulation tasks and schedule. The updated process variables170are provided to the user interface module150for assessment.

In one example, based on the simulation of the one or more operations during the execution phase, a difference between the estimated process variables170at the execution phase and estimated process variables170at the planning phase are computed. The computed difference is added to the estimated process variables170to determine the updated process variables170.

The control system16is exemplary and should not limit the scope of the present disclosure. The functionality of the control system16described herein is also exemplary. The control system16may additionally include other components and capabilities not described herein. The worksite10may additionally include any number of the control system16. The machines12may include a portion the control system16to coordinate work tasks for their portion of the site operations. Further, architecture and capabilities of the control system16may vary without any limitation.

FIG. 3is a graphical representation30showing scheduling of the one or more tasks of the machines12for an exemplary earth moving operation at the worksite10. The earth moving operation shown in the graphical representation30includes the cutting operation and the filling operation. A length of the worksite10in meters (m) and a volume of material180to be cut and filled at the worksite10in m3are plotted along an X-axis and a Y-axis, respectively. As illustrated in theFIG. 3, the worksite10includes multiple cut locations and multiple fill locations. A required level of the worksite10may be indicated at “0” in the Y axis. Material from a cut location ‘C1’ may be removed and filled at a fill location ‘F1’. Material from a cut location ‘C2’ is removed and filled at fill locations ‘F1’ and ‘F2’. Similarly, material from a cut location ‘C3’ is removed and filled at fill locations ‘F2’ and ‘F3’. Material from a cut location ‘C4’ is removed and filled at the fill location ‘F3’. The control system16selects an optimum operating path for multiple trucks employed at the worksite10for performing the cut operation and the fill operation as indicated in the graphical representation30.

FIG. 5is an exemplary table32representing process variables170associated with the one or one or more operations. The process variables170are estimated and tabulated for an exemplary cut and fill operation by the control system16. The process variables170may include, but is not limited to, the operation path of the machines12at the worksite10named as route name, a source station, a destination station, multiple machine specifications, a hauling distance, volume of material180, a unit cost associated with the operating path between the source station and the destination station, a hourly productivity, total working hours, and fuel usage. In one example, for a selected operating path27-22, the source station may be a station number27and the destination station may be a station number22. The hauling distance corresponding to the operating path27-22may be 100 meters. The volume of material180transferred at the operating path27-22may be 1330 cubic meters. The hourly productivity of the operating path27-22may be 336.61. The fuel usage of the machines12for the operating path27-22may be 69.65 Gallons.

In another embodiment, the machines12deployed on the worksites10may also include autonomous machines (not shown) and/or semi-autonomous machines (not shown). In such scenarios, the control system16may be implemented in the planning phase and the execution phase of the one or more operations to be performed at the worksite10as explained earlier. The autonomous machines may be in communication with the control system16. The autonomous machines may include hardware components and/or software components that enable sending of data between the autonomous machines and the control system16. The autonomous machines receive instructions from the control system16. These instructions may include specific machine command and control software applications to be downloaded to the machine prior to or during the execution phase. The movement and/or operation of the autonomous machines may also be regulated based on instructions from the control system16during the execution phase.

INDUSTRIAL APPLICABILITY

The control system16described in the present disclosure may be implemented in the planning phase and the execution phase of the one or more operations such as, but is not limited to, cutting operation, filling operation, construction works, quarrying,_and mining operations performed at the worksite10. The control system16identifies and schedules the one or more task to be performed by the machines12. The scheduling of the one or more task of the machines12enables efficient implementation of the one or more operations at the worksite10. Further, during the execution phase of the one or operations at the worksite10, the control system16is in real time communication with the machines12deployed at the worksite10. This enables the control system16to retrieve real time data from the machines12. The real time data allows monitoring of a progress of the one or more operations at the worksite10efficiently. Further, the real time data is used for updating the process variables170and scheduling the one or more tasks of the machines12. The turn around time of the one or more operations is reduced when the process variables170and the one or more tasks are updated in real time.

FIG. 6is a flow chart of a method34of controlling the machines12for performing the one or more operations at the worksite10. At step36, the control system16receives the data associated with the worksite10. At step38, the control system16receives the resource data120associated with the machines12. At step40, the control system16defines the plurality of constraints160associated with the one or more operations based on the data and the resource data120. At step42, the control system16simulates the one or more operations of the machines12at the worksite10based on the data and the resource data120. Based on the simulation and the plurality of constraints160, the control system16estimates the process variables170associated with the one or more operations at step44. The control system16also schedules one or more tasks to be performed by the machines12at the worksite10, based on the simulation of the one or more operations at step46. At step48, the control system16collects the real time data associated with the one or more operations performed at the worksite10using the communication medium14. Further, at step50, the control system16updates the estimated process variables170associated with the one or more operations and the scheduled one or more tasks of the machines12based on the collected real time data.