System and method for monitoring an earth-moving operation of a machine

A computer-implemented method for monitoring an operation performed by a machine having an implement is provided. The method includes determining a fuel consumption rate value of the machine. The method also includes generating a provisional value based at least in part on the fuel consumption rate value for the operation. The method further includes determining one or more thresholds for the operation. The one or more thresholds correspond to a normal fuel consumption rate value of the machine for the operation. The method further includes generating a status indicator, indicative of a score of the operation based at least in part on a comparison of the provisional value and the one or more thresholds.

TECHNICAL FIELD

The present disclosure relates generally to a system and a method for monitoring an operation performed by a machine, and more particularly relates to a system and a method for monitoring suboptimal conditions of an operation performed by a machine.

BACKGROUND

Machines such as track-type tractors, dozers, motor graders and wheel loaders are used to perform a variety of tasks, including, for example, moving material and/or altering work surfaces at a worksite. In general, these machines may function in accordance with a work plan for a given worksite to perform operations, including digging, loosening, carrying, and any other manipulation of material within a worksite. Furthermore, the work plan may often involve predetermined repetitive tasks that may be entirely or at least partially automated to minimize operator involvement and promote efficiency. A given work environment may involve autonomous and/or semi-autonomous machines that perform tasks in response to preprogrammed commands or delivered commands.

In automated work environments, it is especially desirable to ensure that the machines perform work operations in an efficient and productive manner in accordance with the given work plan. Seemingly minor deviations from the work plan, if undetected or left unaddressed, may be compounded into more significant and obvious errors in the eventual work product. Therefore, early detection of deviations in the work progress or suboptimal machine settings can play an important role in ensuring efficient and productive passes, such as by requesting earlier operator intervention and correction to compensate for the errors. However, in the context of automated work environments, remotely monitoring multiple groups of different machines with a limited number of operators can be challenging.

US Patent Publication No. 2011/0295423 discloses an autonomous machine management system. The autonomous machine management system includes a number of autonomous machines configured to perform area coverage tasks in a worksite and a number of worksite areas within the worksite. A conditional behavior module is provided to be executed by a processor unit and configured to determine whether a number of conditions are met for the number of worksite areas. A navigation system is configured to operate the autonomous machines to perform the area coverage tasks and move between the number of worksite areas when the number of conditions is met.

The above reference provides system and method for controlling operations of a number of autonomous machines in a worksite. However, the reference may not provide sufficient means for monitoring suboptimal conditions of the operations being performed by the autonomous machines.

SUMMARY OF THE DISCLOSURE

In one embodiment of the present disclosure, a computer-implemented method for monitoring an operation performed by a machine having an implement is provided. The method includes determining a fuel consumption rate value of the machine. The method also includes generating a provisional value based at least in part on the fuel consumption rate value for the operation. The method further includes determining one or more thresholds for the operation. The one or more thresholds correspond to a normal fuel consumption rate value of the machine for the operation. The method further includes generating a status indicator, indicative of a score of the operation based at least in part on a comparison of the provisional value and the one or more thresholds.

In another embodiment of the present disclosure, a control system for monitoring an operation performed by a machine having an implement is provided. The control system includes a communication device configured to receive the fuel consumption rate value of the machine. The control system also includes a memory configured to store the fuel consumption rate value. The control system further includes a controller in communication with the memory. The controller is configured to generate the provisional value based at least in part on the fuel consumption rate value for the operation. The controller is further configured to determine one or more thresholds for the operation. The one or more thresholds correspond to the normal fuel consumption rate value of the machine for the operation. The controller is further configured to generate the status indicator, indicative of the score of the operation, based at least in part on the comparison of the provisional value and the one or more thresholds.

In yet another embodiment of the present disclosure, a machine is provided. The machine includes an implement configured to perform an automated earth-moving operation. The machine also includes a metering sensor configured to determine the fuel consumption rate value of the machine for the automated earth-moving operation. The machine further includes a control system configured to monitor the automated earth-moving operation. The control system includes a communication device configured to receive the fuel consumption rate value of the machine. The control system also includes a memory configured to store the fuel consumption rate value. The control system further includes a controller in communication with the memory. The controller is configured to generate the provisional value based at least in part on the fuel consumption rate value for the operation. The controller is further configured to determine one or more thresholds for the operation. The one or more thresholds correspond to the normal fuel consumption rate value of the machine for the operation. The controller is further configured to generate the status indicator, indicative of the score of the operation, based at least in part on the comparison of the provisional value and the one or more thresholds.

DETAILED DESCRIPTION

Reference will now be made in detail to specific aspects or features, examples of which are illustrated in the accompanying drawings. Wherever possible, corresponding or similar reference numbers will be used throughout the drawings to refer to the same or corresponding parts.

FIG. 1illustrates a perspective view of a worksite100having a work surface102. The worksite100may be, for example, a mine site, a landfill, a quarry, a road site, a farm, a construction site, or any other similar type of worksite. Further one or more machines104, as depicted inFIG. 1, are provided to perform predetermined operations in the worksite100. The predetermined operations may be associated with altering the work surface102, such as a dozing operation, a grading operation, a leveling operation, a bulk material removal operation, or any other type of operation that results in geographical modifications within the worksite100. For example, the machines104may be configured to excavate areas of the worksite100according to one or more predefined excavation plans. The excavation plans may include, among other things, defining the location, size, and shape of a plurality of cuts intended in the work surface102at the worksite100.

In the illustrated embodiment of the present disclosure, the machines104may be automated or semi-automated machines, or any type of manually operated machines configured to perform operations associated with industries related to mining, construction, farming, or any other industry known in the art. The machines104, for example, may embody earth moving machines, such as dozers having traction devices106, such as tracks, wheels, or the like. Alternatively, the machine104may be an off-highway vehicle, such as an excavator, a backhoe, a loader, a motor grader, or any other vehicle for performing various earth moving operations. As illustrated, the machines104may include implements108, such as, movable blades or any other machine implements, configured to perform the requisite earth-moving operations at the worksite100.

The present disclosure provides a control system110configured to at least partially manage operations of the machines104and the implements108within the worksite100. The control system110may be embodied in any number of different configurations. In an embodiment, as illustrated inFIG. 1, the control system110may be implemented in a computing device (not shown) disposed in a command center112. The command center112may be located remotely and/or locally relative to the worksite100. In other embodiments, the control system110may be implemented in a computing device (not shown) disposed on-board in any one or more of the machines104, such as, manually operated machines. In some other embodiments, the control system110may be partially implemented in the computing device disposed on-board the machines104, and partially in the computing device disposed in the command center112. In still other embodiments, the control system110may be implemented in a mobile device113with the operator, where the operator may be monitoring the machines104locally and/or remotely relative to the worksite100and/or the machines104. In yet other embodiments, the control system110may partially be implemented in a cloud based server (not shown) and partially in the computing device disposed in the command center112or on-board the machine104or the mobile device113.

Each of the machines104may include one or more feedback devices114capable of signaling, tracking, monitoring, or otherwise transmitting machine parameters or other related information to the control system110. The machine parameters may include information, such as, but not limited to, machine slope, machine slip, fuel consumption rates, implement power, pass duration, pass distance, engine speed, engine load, and the like. The feedback devices114may communicate with one or more satellites116, which in turn, may communicate the information to the control system110. Each of the machines104may also include a location sensor118configured to communicate various information pertaining to the position and/or orientation information of the machines104relative to the worksite100to the control system110, via the feedback devices114. The machines104may additionally include one or more implement sensors120configured to track and communicate position and/or orientation information of the implements108to the control system110.

The machines104may also include metering sensors122configured to determine a fuel consumption rate value ‘F’ in the machines104. The metering sensor122may determine the fuel consumption rate value ‘F’ based on measuring a flow rate of fuel in the machine104or by any other known technique in the art. The metering sensors122, in various machines104, may be one of an optical flow meter, a magnetic flow meter, an ultrasonic flow meter or any other flow meters capable of being implemented in the machine104to provide a reading of the fuel consumption rate value ‘F’. The fuel consumption rate value ‘F’ may be an instantaneous flow rate of the fuel in the machine104. Alternatively, the fuel consumption rate value ‘F’ may be the flow rate of the fuel over predefined intervals. The metering sensor122may further be configured to communicate the fuel consumption rate value ‘F’ to the control system110via the feedback devices114.

FIG. 2illustrates an embodiment of the control system110that may be used in conjunction with the machines104. The control system110may include a memory124and a controller126in communication with each other. The memory124may be provided either on-board relative to the controller126or external to the controller126in communication therewith over a data bus or the like. The memory124may include non-transitory computer-readable medium or memory, such as a disc drive, flash drive, optical memory, magnetic drive, or the like. The memory124may retrievably store one or more algorithms having a set of instructions to manage the machines104and the implements108in the worksite100. The controller126, on the other hand, may be a logic unit using any one or more of a processor, a microprocessor, a microcontroller, or any other suitable means. The controller126may be configured to execute the one or more algorithms stored in the memory124.

The control system110may also include one or more communication devices128. The communication device128, also illustrated inFIG. 1, may be configured to communicate with the feedback devices114disposed in the machines104, for example, via the satellites116, or any other suitable means of communication. The communication device128may be configured to receive data from the location sensors118, the implement sensors120, the metering sensors122, among other sensors in the machines104via the feedback devices114. For instance, the communication devices128may enable the controller126to receive data pertaining to the position and/or orientation of the machines104and the implements108.

Referring toFIG. 3, the machine104is shown performing an operation ‘O’ in the worksite100. The operation ‘O’ may be a manual operation, a semi-automated operation or an automated operation based on the requirements of the operation. The operation ‘O’ may be an automated earth-moving operation. The operation ‘O’ may be planned along a cut profile130and, for instance, be defined as a repeatable cycle including the operations of engaging a cut at a first cut location132, loading material into the implement108of the machine104, carrying or dumping the loaded material over a crest134of the worksite100, and returning the machine104to a subsequent or a second cut location136. The control system110may further be able to define specific operations planned for certain areas in the worksite100, such as a pass, a cut, an implement path and a loading profile within the operation ‘O’. Hereinafter, the terms “operation”, “automated operation”, “earth-moving operation” and “automated earth-moving operation” have been interchangeably used.

In an embodiment, the control system110may be configured for monitoring the operation ‘O’ performed by the machine104. The control system110may be configured to generate a score ‘S’ of the operation ‘O’ performed by the machine104. The score ‘S’ may be indicative of one or more of the productivity, profitability and efficiency of the operation ‘O’. For the purpose of the present disclosure, the terms productivity, profitability and efficiency are interchangeably used hereinafter. The score ‘S’ may be defined in the form of percentage of current productivity of the operation ‘O’, measured based on some parameters, to peak productivity possible for the operation ‘O’ measured based on same parameters. In such case, the score ‘S’ with value equivalent to 90% may therefore be indicative that the operation ‘O’ is being performed with 90% productivity. A peak score of the operation may be indicative that the operation ‘O’ is being performed with peak productivity.

In an embodiment, the control system110may further be configured to generate a status indicator indicative of the score ‘S’ of the operation ‘O’. The status indicators may assist the operator to monitor and assess the productivity of the operation ‘O’, and identify any suboptimal conditions of the machine104during the operation ‘O’. The status indicator may be generated as different types of status indicator that provide different indications for different ranges of the score ‘S’. The different types of status indicator may be represented using different color-coded schemes. Alternatively, the status indicators may be provided using other visual cues, audible and/or haptic schemes that are easily noticeable and suited to promptly indicate suboptimal conditions to the operator.

In the control system110, the controller126may be configured to sequentially perform calculations according to the one or more algorithms in order to generate the status indicator. The communication device128may be configured to receive the fuel consumption rate value ‘F’ of the machine104. The fuel consumption rate value ‘F’ may be stored in the memory124of the control system110. The fuel consumption rate value ‘F’ may be temporarily stored in the memory124to be retrieved by the controller126.

The fuel consumption rate value ‘F’ may peak when the peak productivity of the operation O′ is reached. When the machine104is underpowered and not performing the operation ‘O’ at peak productivity, for example in a loading operation where the load carried by the machine104is lower than the load capacity of the machine104, or in a cutting operation when a depth of cut is lower than desired, the fuel consumption rate value ‘F’ may eventually drop. In other condition, where the machine is overpowered due to slippage of the traction devices106, the fuel consumption rate value ‘F’ may eventually drop again as the machine104now requires lesser amount of fuel to spin the traction devices106.

The controller126may be configured to generate a provisional value ‘P’ based at least in part on the fuel consumption rate value ‘F’ for the operation ‘O’. The provisional value ‘P’ may take many forms as per the requirement of monitoring the operation ‘O’. For example, the provisional value ‘P’ may be equivalent to the fuel consumption rate value ‘F’, and is generated directly as the fuel consumption rate value ‘F’ of the machine104. In an embodiment, the provisional value ‘P’ may be equivalent to an average fuel consumption rate value ‘A’, and is generated by averaging the instances of the fuel consumption rate values ‘F’ of the machine104during the course of the operation ‘O’. In other embodiments, the provisional value ‘P’ may use some other variations of the fuel consumption rate value ‘F’, such as, but not limited to, normalized fuel consumption rate value, average normalized fuel consumption rate value, or any other possible variation for the purpose.

The controller126may further be configured to determine a normal fuel consumption rate value ‘N’ for the operation ‘O’. The normal fuel consumption rate value ‘N’ may be indicative of the peak score of the operation ‘O’. In one example, the normal fuel consumption rate value ‘N’ may be equivalent to the fuel consumption rate value ‘F’ of the machine104, when the machine104is performing the operation ‘O’ with the peak score. In other example, the normal fuel consumption rate value ‘N’ may be equivalent to the average fuel consumption rate value ‘A’ of the machine104, when the machine104is performing the operation ‘O’ with the peak score. The normal fuel consumption rate value ‘N’ may be predefined or dynamically generated based on the machine parameters during the operation ‘O’.

The controller126may further be configured to determine one or more thresholds for the operation ‘O’. The one or more thresholds may be determined based on the normal fuel consumption rate value ‘N’ for the operation ‘O’. The one or more thresholds may correspond to the normal fuel consumption rate value ‘N’. In an embodiment, the controller126may be configured to determine two thresholds, a first threshold and a second threshold. It may be understood that the controller126may be configured to determine fewer or more thresholds. In an example, the first threshold may be equivalent to 60% of the normal fuel consumption rate value ‘N’, and the second threshold may be equivalent to 80% of the normal fuel consumption rate value ‘N’. It may be understood that the aforementioned percentages are exemplary only, and may vary as per the requirements of monitoring the operation ‘O’.

The controller126may further be configured to generate the status indicator. The status indicator is generated based on a comparison of the provisional value ‘P’ and the one or more thresholds. In an embodiment, the controller126may be configured to generate three types of status indicators based on the comparison of the provisional value ‘P’ and the one or more thresholds. The status indicator is generated as one of a critical status indicator ‘S1’, a cautionary status indicator ‘S2’, and a normal status indicator ‘S3’. The critical status indicator S1 may be generated when the provisional value ‘P’ is less than or equal to the first threshold. The cautionary status indicator S2 is generated when the provisional value ‘P’ may be greater than the first threshold but less than or equal to the second threshold. The normal status indicator ‘S3’ is generated when the provisional value ‘P’ may be greater than both of the first threshold and the second threshold.

The controller126may also be configured to generate the score ‘S’ of the operation ‘O’. The score ‘S’ may be generated based on a comparison of the provisional value ‘P’ and the normal fuel consumption rate value ‘N’. For example, the score ‘S’ may be generated as a ratio or a percentage of the provisional value ‘P’ to the normal fuel consumption rate value ‘N’. The score ‘S’ may be a numerical value indicative of the productivity of the operation ‘O’ performed by the machine104. The score ‘S’ having a percentage of 100% or a ratio of 1 corresponds to the peak score and indicates that the machine104may be operating at peak productivity for at least the operation ‘O’ or particular stages of the operation ‘O’. The score ‘S’ substantially lower than 100% or1may indicate suboptimal productivity of the operation ‘O’. Therefore higher the score ‘S’, the higher the productivity of the operation ‘O’ and vice-versa. In some embodiments, the score ‘S’ may be used for generating the status indicator.

The controller126may be configured to generate the provisional value ‘P’ at predefined intervals during the operation ‘O’. Accordingly, the controller126may be configured to update the status indicator after each predefined interval based on the provisional value ‘P’. Further as discussed above, the operation ‘O’ may include multiple repeatable cycles of the operation ‘O’. In such cases, the controller126may be configured to apply the provisional value ‘P’ generated for a prior cycle as the provisional value ‘P’ for a subsequent cycle. The controller126may additionally be configured to reset the provisional value ‘P’ based on a change in the machine parameters in the subsequent cycle.

FIGS. 4-6illustrate three different embodiments of the controller126showing some of the possible configurations of the controller126to implement the algorithms for generating the status indicator. In particular, the embodiments ofFIGS. 4-6show the controller126being implemented in three different configurations. InFIG. 4, the controller126is shown as a first controller140. InFIG. 5, the controller126is shown as a second controller150. InFIG. 6, the controller126is shown as a third controller160. It may be understood that any one of the first controller140, the second controller150or the third controller160may be employed as the controller126in the control system110based on the consideration of the parameters for generating the status indicator, as discussed in detail hereinafter.

InFIG. 4, a first controller140is illustrated in which the one or more algorithms may be generally categorized to include a first pass identification module142, a first determination module144and a first status indicator module146. InFIG. 5, a second controller150is illustrated in which the one or more algorithms may be generally categorized to include a second pass identification module152, a second averaging module154, a second determination module156and a second status indicator module158. InFIG. 6, a third controller160is illustrated in which the one or more algorithms may be generally categorized to include a third pass identification module162, a third normalization module164, a third averaging module166, a third determination module168and a third status indicator module170. It may be noticed that a first averaging module, and a first normalization module and a second normalization module have not been defined. These have been deliberately omitted for clear understanding of the present disclosure.

The pass identification modules142,152,162may configure the respective controllers140,150,160to determine if the machine104is currently operational and whether the machine104is currently performing the operation ‘O’. The pass identification modules142,152,162may also configure the controllers140,150,160to determine the current stage of the operation ‘O’, that is, a cut operation, a pass operation, an idle operation, or any other stage of the operation ‘O’ by processing the machine parameters. The pass identification modules142,152,162may also configure the controllers140,150,160to spatially identify and define the operation ‘O’ to be performed relative to the worksite100. Based on the desired application, the pass identification modules142,152,162may further configure the controllers140,150,160to define each operation ‘O’ or cycle to include other combinations of operations.

In the second controller150, when the machine104starts performing the operation ‘O’, as determined by the second pass identification module152, the second averaging module154may configure the second controller150to begin generating or otherwise calculating the average fuel consumption rate value ‘A’, as the provisional value ‘P’, associated with the operation ‘O’. The average fuel consumption rate value ‘A’ may be generated based on the fuel consumption rate value ‘F’ stored in the memory124, as received by the communication devices128. In this manner, the second averaging module154may configure the second controller150to continue generating the average fuel consumption rate value ‘A’ for the duration of the given operation ‘O’, such as at predefined intervals of time, distance, or any other designations. Alternatively, the second averaging module154may generate the average fuel consumption rate value ‘A’ once per operation ‘O’ or cycle. Still alternatively, the second averaging module154may update the average fuel consumption rate value ‘A’ for every fuel consumption rate value ‘F’ that is received during the operation ‘O’.

In the third controller160, when the machine104starts performing the operation ‘O’, as determined by the third pass identification module162, the third normalization module164may configure the third controller160to begin generating or otherwise calculating a normalized fuel consumption rate value ‘NF’ associated with the machine104. The normalized fuel consumption rate value ‘NF’ may be generated as a percentage or ratio of the fuel consumption rate value ‘F’ to the normal fuel consumption rate value ‘N’. Correspondingly, a normalized fuel consumption rate value ‘NF’ having a percentage of 100% or a ratio of 1 indicates that the machine104may be operating at peak productivity for at least the operation ‘O’ or particular stages of the operation ‘O’. The normalized fuel consumption rate value ‘NF’ substantially lower than 100% or 1 may indicate suboptimal productivity of the operation ‘O’ due to the machine104being underpowered and carrying lower volume of loads, or the like, or the machine104being overpowered and exhibiting higher rates of slip of the traction devices106, or the like.

Moreover in the third controller160, while the third normalization module164generates the normalized fuel consumption rate value ‘NF’, the third averaging module166may configure the third controller160to generate an average normalized fuel consumption rate value ‘AN’, as the provisional value ‘P’, for the operation ‘O’. For example, the third averaging module166may generate the average normalized fuel consumption rate value ‘AN’, as the average of the normalized fuel consumption rate values generated during the course of the operation ‘O’. Alternatively, the third averaging module166may generate the average normalized fuel consumption rate value ‘AN’ once per operation ‘O’ or cycle. Still alternatively, the third averaging module166may update the average normalized fuel consumption rate value ‘AN’ for every normalized fuel consumption rate value ‘NF’ that is calculated by the third normalization module164for duration of the operation ‘O’.

Referring back toFIGS. 4-6, the determination modules144,156,168may configure the respective controllers140,150,160to determine one or more thresholds. The thresholds may be determined based on the operation ‘O’ being carried out by the machines104. The determination modules144,156,168may configure the controllers140,150,160to automatically and/or dynamically adjust the thresholds based on detected changes in the machine104, worksite100, or other factors. Then again, the determination modules144,156,168may configure the controllers140,150,160to allow the operator to manually modify including predefine or change the one or more thresholds.

The determination modules144,156,168may configure the respective controllers140,150,160to determine two thresholds in each case. For instance, the first determination module144may configure the first controller140to determine a first threshold ‘TF1’ and a second threshold ‘TF2’ for the fuel consumption rate value ‘F’. The second determination module156may configure the second controller150to determine a first threshold ‘TA1’ and a second threshold ‘TA2’ for the average fuel consumption rate value ‘A’. The third determination module168may configure the third controller160to determine a first threshold ‘TN1’ and a second threshold ‘TN2’ for the average normalized fuel consumption rate value ‘AN’. The determination modules144,156,168may configure the controllers140,150,160with fewer or more thresholds as per the requirements for lesser or more status indicators for the operation ‘O’.

Using one or more thresholds, the status indicator modules146,158,170may configure the respective controllers140,150,160to generate the status indicator. Specifically, the first status indicator module146may configure the first controller140to qualify the fuel consumption rate value ‘F’ based on a comparison with the thresholds TF1, TF2. The second status indicator module158may configure the second controller150to qualify the average fuel consumption rate value ‘A’ based on a comparison with the thresholds TA1, TA2. The third status indicator module170may configure the third controller160to qualify the average normalized fuel consumption rate value ‘AN’ based on a comparison with the thresholds TN1, TN2.

In an embodiment, the status indicator modules146,158,170may configure the respective controllers140,150,160to selectively generate one of the critical status indicator ‘S1’, the cautionary status indicator ‘S2’, and the normal status indicator ‘S3’. In the first controller140, the first status indicator module146may configure the first controller140to generate the critical status indicator ‘S1’ when the fuel consumption rate value ‘F’ is less than or equal to the first threshold ‘TF1’. The cautionary status indicator ‘S2’ may be generated when the fuel consumption rate value ‘F’ is greater than the first threshold ‘TF1’ but less than or equal to the second threshold ‘TF2’. The normal status indicator ‘S3’ may be generated when the fuel consumption rate value ‘F’ is greater than both of the first threshold ‘TF1’ and the second threshold ‘TF2’. Moreover, the first status indicator module146may configure the first controller140to update the status indicator for each consecutive fuel consumption rate value ‘F’ that is determined.

Similarly in the second controller150, the second status indicator module158may configure the second controller150to generate the critical status indicator ‘S1’ when the average fuel consumption rate value ‘A’ is less than or equal to the first threshold ‘TA1’. The cautionary status indicator ‘S2’ may be generated when the average fuel consumption rate value ‘A’ is greater than the first threshold ‘TA1’ but less than or equal to the second threshold ‘TA2’. The normal status indicator ‘S3’ may be generated when the average fuel consumption rate value ‘A’ is greater than both of the first threshold ‘TA1’ and the second threshold ‘TA2’. Moreover, the second status indicator module158may configure the second controller150to update the status indicator for each consecutive average fuel consumption rate value ‘A’ that is generated by the second averaging module154.

And similarly in the third controller160, the third status indicator module170may configure the third controller160to generate the critical status indicator ‘S1’ when the average normalized fuel consumption rate value ‘AN’ is less than or equal to the first threshold ‘TN1’. The cautionary status indicator ‘S2’ may be generated when the average normalized fuel consumption rate value ‘AN’ is greater than the first threshold ‘TN1’ but less than or equal to the second threshold ‘TN2’. The normal status indicator ‘S3’ may be generated when the average normalized fuel consumption rate value ‘AN’ is greater than both of the first threshold ‘TN1’ and the second threshold ‘TN2’. Moreover, the third status indicator module170may configure the third controller160to update the status indicator for each consecutive average normalized fuel consumption rate value ‘AN’ that is generated by the third averaging module166.

In the illustrated embodiment ofFIG. 2, the control system110is further shown to include one or more output devices172. The output devices172may be configured to receive the status indicator directly from the controller126. Otherwise, the communication devices128may be configured to receive the status indicator from the controller126and transmit the status indicator to the output devices172. The output devices172may employ any combination of display screens, touchscreens, light-emitting diodes (LEDs), speakers, haptic devices, and the like, to provide one or more of visual, audible and/or haptic indications to the operator of the machines104.

In an embodiment, the output devices172may be disposed in the command center112from where the operator may be monitoring and/or controlling the operations of the machine104, such as for the machines104to be operated autonomously. In other embodiments, the output devices172may be disposed on-board within the machines104, such as for the machines104to be operated manually. In still other embodiments, the output devices172may be disposed in the command center112or the machines104, or partially in the command center112and partially in the machines104, such as for semi-autonomous machines. Alternatively, the output device172may be in the form of a mobile device, such as a smartphone, a tablet, a PDA, or the like which enables the operator to remotely monitor the status of the work being performed.

FIG. 7illustrates an exemplary embodiment of an operator interface174for the one or more output devices172. The output devices172may be configured to communicate the status indicator to the operator via the operator interface174. The output devices172may also be configured to communicate information to the operator corresponding to the operating conditions of the machine104, the progress of the work or operation being performed, and any other indications of efficiency, productivity, errors, deviations, suboptimal operating conditions, and the like via the operator interface174. The operator interface174may be able to communicate such information based at least in part on the status indicator generated by the controller126. The operator interface174ofFIG. 7is exemplary only and may be modified to include or exclude some parameters as per the requirement of monitoring, assessing and/or controlling the operation ‘O’ performed by the machine104.

In an embodiment, the different types of the status indicator may be communicated using a color-coded scheme. For example, as representatively illustrated inFIG. 7, a critical status indicator ‘S1’ may be presented in ‘RED’ in the operator interface174to indicate that the machine104is carrying out the operation ‘O’ with a poor score ‘S’ and that operator intervention may be required. A cautionary status indicator ‘S2’ may be presented in ‘YELLOW’ to indicate that the machine104is carrying out the operation ‘O’ at a suboptimal but acceptable score ‘S’, and to serve as a warning that operator intervention may be required. Correspondingly, a normal status indicator ‘S3’ may be presented in ‘GREEN’ in the operator interface174to indicate that the operation ‘O’ is being carried out at or near a peak score and that no intervention may be required at the moment.

In some modifications, the status indicator may be communicated using different color-coded schemes or any other visual cues that are easily noticeable and suited to promptly indicate suboptimal conditions to the operator. In other modifications, the different types of status indicator may be communicated using audible and/or haptic schemes. In further modifications, the operator interface174may also communicate the score ‘S’ of the operation ‘O’ directly to the operator. In still further modifications, the operator interface174may also communicate some additional information, instructions and/or suggestions relating to the different types of status indicator which may guide the operator in correcting any issues or deficiencies detected during the operation ‘O’.

INDUSTRIAL APPLICABILITY

The present disclosure provides system and method for monitoring an operation performed by a machine. The present disclosure provides system and method to guide the machines in an efficient, productive and predictable manner in the worksite. In particular, the present disclosure provides system and method that enable earlier detection and flagging of suboptimal operating conditions or deviations from the work plan which may potentially impact overall productivity. Although applicable to any type of machine, the present disclosure may be particularly applicable to autonomously or semi-autonomously controlled dozing machines where the dozing machines are controlled to perform automated earth-operations in a worksite. The present disclosure provides a score of an operation indicative of a productivity rating of the machine for the given operation. Specifically, the present disclosure provides a status indicator, indicative of the score, to simplify the assessment of work productivity for the operator of the machines and helps the operator to promptly respond or intervene as necessary.

FIG. 8diagrammatically illustrates a computer implemented method200for monitoring the operation ‘O’ performed by the machine104, according to which the first controller140may be configured to operate. As shown in step202, the method200includes determining the fuel consumption rate value ‘F’ of the machine104. The fuel consumption rate value ‘F’ may be determined by the metering sensor122as described above and further stored and retrieved from the memory124as necessary. The method200may further include determining whether the machine104is currently performing the operation ‘O’. Further in step204, the method200includes generating the provisional value ‘P’ based at least in part on the fuel consumption rate value ‘F’.

In step206, the method200includes determining one or more thresholds for the operation ‘O’. The thresholds may correspond to the normal fuel consumption rate value ‘N’ of the machine104for the operation ‘O’. The normal fuel consumption rate value ‘N’ may be indicative of the fuel consumption rate value ‘F’ for the peak score of the operation ‘O’. The method200may include comparing the provisional value ‘P’ and the thresholds. Further in step208, the method200includes generating the status indicator, indicative of the score ‘S’ of the operation ‘O’, based at least in part on the comparison of the provisional value ‘P’ and the one or more thresholds.

Moving on,FIG. 9illustrates a detailed embodiment of another exemplary algorithm or a computer implemented method300for monitoring the operation ‘O’, as implemented in the second controller150. In step302, the method300includes determining the fuel consumption rate value ‘F’. In step304, the method300includes determining whether the machine104is performing the operation ‘O’ based on the fuel consumption rate value ‘F’ or other machine parameters. In step304, when it is determined that the machine104is currently performing the operation ‘O’, the average fuel consumption rate value ‘A’ is generated, as shown in step306. The average fuel consumption rate value ‘A’ may be generated as the provisional value ‘P’ for the operation ‘O’. The second controller150may additionally be configured to determine the thresholds TA1, TA2.

In step308, the second controller150may be configured to check whether a new cycle of the operation ‘O’ has started. Specifically, the second controller150may additionally monitor progress of the machine104to determine whether the current cycle of the operation ‘O’ is still progressing, or whether the machine104has completed the initial cycle and is starting a new cycle. If the machine104is determined to be continuing along the initial cycle, the second controller150may use a prior average fuel consumption rate value ‘AP’, that is the average fuel consumption rate value ‘A’ from the prior cycle. The prior average fuel consumption rate value ‘AP’ may be retrieved from the memory124. Further the second controller150, as shown in step310, may be configured to compare the prior average fuel consumption rate value ‘AP’ and one or more thresholds TA1, TA2 and generate the status indicator. In step310, the second controller150may additionally be configured to initially switch-off all the status indicators as provided in the operator interface174ofFIG. 7.

As illustrated, in step312, if the prior average fuel consumption rate value ‘AP’ is less than or equal to the first threshold ‘TA1’, the second controller150generates a critical status indicator ‘S1’, as shown in step314. The critical status indicator ‘S1’ may be generated in ‘RED’ to indicate low productivity and to suggest to an operator that at least some manual intervention or correction of the machine104may be needed to restore acceptable productivity levels. Further in step316, if the prior average fuel consumption rate value ‘AP’ satisfies the first threshold ‘TA1’, but is less than or equal to the second threshold ‘TA2’, the second controller150generates the cautionary status indicator ‘S2’, as illustrated in step318. The cautionary status indicator ‘S2’ may be generated in ‘YELLOW’ to indicate suboptimal but acceptable productivity and to warn the operator of potentially adverse deviations from the planned operation. If the prior average fuel consumption rate value ‘AP’ satisfies both of the first and second thresholds TA1, TA2, the second controller150generates the normal status indicator ‘S3’, as illustrated in step318. The normal status indicator ‘S3’ may be generated in ‘GREEN’ to indicate desired productivity to the operator.

As shown in step322, if a new cycle is detected in step308, the second controller150may apply the average fuel consumption rate value ‘A’, as generated in step306, to replace the prior average fuel consumption rate value ‘AP’. That is, the second controller150may apply the average fuel consumption rate value ‘A’, as generated in step306, as the average fuel consumption rate value ‘A’ from which the new cycle may be assessed. In step324, the second controller150may additionally reset the average fuel consumption rate value ‘A’ to adjust for any detected changes in the machine parameters, work environment, or other factors since the previous cycle. Furthermore, once all updates have been made, the second controller150may proceed to generate the status indicator as discussed in the steps above. The second controller150may continue updating the average fuel consumption rate value ‘A’ and the status indicator using the average fuel consumption rate value ‘A’ for each cycle, or at predefined intervals of time, distance, or other designations within each cycle of the operation ‘O’.

FIG. 10illustrates a method400for monitoring the operation ‘O’, as implemented in the third controller160. The method400may use a different parameter, the average normalized fuel consumption rate value ‘AN’ instead of the average fuel consumption rate value ‘A’ as described in the method300above. In general, the method400includes determining the fuel consumption rate value ‘F’, as shown in step402. The method400further includes determining whether the machine104is currently performing operation ‘O’, as shown in step404. Further in step406and408, the method400includes generating the normalized fuel consumption rate value ‘NF’ and the average normalized fuel consumption rate value ‘AN’ respectively, as described above.

In step410, the method400includes determining whether the current cycle is in progress or a new cycle has started. Specifically, the third controller150may additionally monitor progress of the machine104to determine whether the current cycle of the operation ‘O’ is still progressing, or whether the machine104has completed the initial cycle and is starting a new cycle. If the machine104is determined to be continuing along the initial cycle, the third controller160may use a prior average normalized fuel consumption rate value ‘ANP’, that is the average normalized fuel consumption rate value ‘AN’ from the prior cycle. The prior average normalized fuel consumption rate value ‘ANP’ may be retrieved from the memory124. The method400includes comparing the prior average normalized fuel consumption rate value ‘ANP’ with the thresholds TN1, TN2 to generate the status indicator, as shown in step412.

In step414, if the prior average normalized fuel consumption rate value ‘ANP’ is less than or equal to the first threshold ‘TN1’, then the critical status indicator ‘S1’ is generated, as shown in step416. Further in step418, if the prior average normalized fuel consumption rate value ‘ANP’ is greater than the first threshold ‘TN1’ but less than or equal to the second threshold ‘TN2’, then the cautionary status indicator ‘S2’ is generated, as shown in step420. If the prior average normalized fuel consumption rate value ‘ANP’ is greater than both the thresholds TN1, TN2, the normal status indicator ‘S3’ is generated, as shown in step422.

As shown in step410, if a new cycle is detected, the third controller160, as shown in step424, may apply the average normalized fuel consumption rate value ‘AN’, as generated in step408, to replace the prior average normalized fuel consumption rate value ‘ANP’. That is, the third controller160may apply the average normalized fuel consumption rate value ‘AN’, as generated in step408, as the average normalized fuel consumption rate value ‘AN’ from which the new cycle may be assessed. Further, in step426, the third controller160may additionally reset the average normalized fuel consumption rate value ‘AN’ to adjust for any detected changes in the machine parameters, work environment, or other factors since the previous cycle and subsequently proceed to generate the status indicator. The third controller160may continue updating the average normalized fuel consumption rate value ‘AN’ and the status indicator using the average normalized fuel consumption rate value ‘AN’ for each cycle, or at predefined intervals of time, distance, or other designations within each cycle of the operation ‘O’.

While aspects of the present disclosure have been particularly shown and described above, it will be understood by those skilled in the art that various additional aspects may be contemplated by the modification of the disclosed machines, systems and methods without departing from the spirit and scope of what is disclosed. Such aspects should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.