Simulation system implementing historical machine data

A simulation system for a machine is disclosed. The simulation system has a user interface configured to display a simulated environment, and a controller in communication with the user interface. The controller is configured to receive historical information related to performance of a machine, and recreate a past operation of the machine from the received historical information. The controller is also configured to provide to the user interface the recreated past operation for display in the simulated environment.

TECHNICAL FIELD

This disclosure relates generally to a simulation system and, more particularly, to a system that uses previously recorded performance data to simulate past operation of a machine and recommend related training exercises.

BACKGROUND

Machines such as, for example, construction equipment, passenger vehicles, vocational trucks, and other machines known in the art are used for a variety of purposes. Before, during, and after operation of these machines, it may be important to know or predict the performance of the machines and their operators. However, depending on the type of the machine, size of the machine, cost of the machine, and/or the current application and location of the machine, this information may be difficult and expensive to access.

One solution to this problem that has been implemented by machine manufacturers is described in U.S. Patent Publication No. 2003/0120472 (the '472 publication) by Lind published on Jun. 26, 2003. The '472 publication describes a process for simulating one or more components for a user. The process includes creating an engineering model of a component, receiving from the user selection data for configuring the component, and creating a web-based model of the component based on the selection data and the engineering model. The process further includes providing a simulation of the web-based model in a simulation environment and providing to the user feedback data reflecting characteristics of the web-based model during the simulation.

Although the process of the '472 publication may allow a user to operate the configured component in a simulated environment to predict how the component might function, it does not provide a glimpse of past or current actual component performance or information regarding historical operator control of the component. Without knowing or being able to visualize how the component has been or is currently being used, it may be difficult to analyze past performance of the machine or it's operator, or make improvement recommendations to machine operators.

The system of the present disclosure is directed towards overcoming one or more of the problems as set forth above.

SUMMARY OF THE INVENTION

In accordance with one aspect, the present disclosure is directed toward a machine simulation system. The machine simulation system includes a user interface configured to display a simulated environment, and a controller in communication with the user interface. The controller is configured to receive historical information related to performance of a machine, and recreate a past operation of the machine from the received historical information. The controller is further configured to provide to the user interface the recreated past operation for display in the simulated environment.

According to another aspect, the present disclosure is directed toward a method of improving machine operation. The method includes receiving historical information related to performance of the machine, and recreating a past operation of the machine from the received historical information. The method also includes displaying the recreated past operation in a simulated environment.

DETAILED DESCRIPTION

FIG. 1illustrates an exemplary machine10performing a predetermined function at a worksite12. Machine10may embody a stationary or mobile machine, with the predetermined function being associated with a particular industry such as mining, construction, farming, transportation, power generation, or any other industry known in the art. For example, machine10may be an earth moving machine such as the excavator depicted inFIG. 1, in which the predetermined function includes the removal of earthen material from worksite12that alters the geography of worksite12to an architecturally desired form. Machine10may alternatively embody a different earth moving machine such as a motor grader or a wheel loader, or a non-earth moving machine such as a passenger vehicle, a stationary generator set, or a pumping mechanism. Machine10may embody any suitable operation-performing machine.

As illustrated inFIG. 2, machine10may include a simulation system14having multiple components that interact to monitor the operation of machine10and perform analysis in response thereto. In particular, machine10may include a data module18, a controller20, and a display system22. It is contemplated that any one or all of data module18, controller20, and display system22may be integrated in a single unit, if desired. It is further contemplated that simulation system14may include additional or different components than those illustrated inFIG. 2.

Data module18may include a plurality of sensing devices18a-edistributed throughout machine10to gather data from various components and systems of machine10. Sensing devices18a-emay be associated with, for example, operator input device, a work tool24, a power source26, a transmission device28, one or more hydraulic devices30, a position locating device32, a torque converter (not shown), a fluid supply (not shown), and/or other systems and components of machine10. These sensing devices18a-emay automatically gather data from machine10such as operator manipulation of the input devices, tool, power source, and/or machine velocity and location; fluid pressure, flow rate, temperature, contamination level, and/or viscosity; electric current and/or voltage levels; fluid (i.e., fuel, oil, water, etc.) consumption rates; loading levels (i.e., payload value, percent of maximum allowable payload limit, payload history, payload distribution, etc.); transmission output ratio; cycle time; idle time, grade; recently performed maintenance and/or repair operations; and other such pieces of information. Additional information may be generated or maintained by machine data module18such as the date, time of day, and operator information. The gathered data may be indexed relative to the time, day, date, operator, or other pieces of information to trend the various operational aspects of machine10, if desired.

Controller20may be in communication with data module18and include any means for monitoring, recording, storing, indexing, processing, and/or communicating the operational aspects of machine10described above. These means may include components such as, for example, a memory, one or more data storage devices, a central processing unit, or any other components that may be used to run an application. Furthermore, although aspects of the present disclosure may be described generally as being stored in memory, one skilled in the art will appreciate that these aspects can be stored on or read from different types of computer program products or computer-readable media such as computer chips and secondary storage devices, including hard disks, floppy disks, flash drives, optical media, CD-ROM, or other forms of RAM or ROM.

Controller20may further include a means for communicating with an offboard system34. For example, controller20may include hardware and/or software that enables sending and receiving of data messages through a direct data link (not shown) or a wireless communication link (not shown). The wireless communications may include satellite, cellular, infrared, and any other type of wireless communications that enable controller20to exchange information. It is contemplated that a separate module may alternatively be included within simulation system14to facilitate the communication of data between controller20and offboard system34, if desired.

Offboard system34may represent one or more receiving, computing, and/or display systems of a business entity associated with machine10, such as a manufacturer, dealer, retailer, owner, service provider, or any other entity that generates, maintains, sends, and/or receives information associated with machine10. The one or more computing systems may include, for example, a machine simulator, a mainframe, a work station, a laptop, a personal digital assistant, and other computing systems known in the art.

As illustrated inFIG. 3, display system22may provide to an operator of machine10an onboard visual indication of the performance of machine10. For example, display system22may be configured to receive from controller20position, orientation, and/or velocity information associated with the movement of machine10and/or work tool24relative to worksite12, and graphically display this information. In one example, display system22may embody a monitor36located within an operator station38of machine10(referring toFIG. 1). Monitor36may receive the information from controller20and display a real time location of machine10and/or work tool24relative to worksite12, and one or more efficiency warnings and measures. In one exemplary embodiment, monitor36may include an efficiency warning lamp42, a fuel consumption readout44, and a cycle time readout46. It is contemplated that different or additional efficiency warnings and/or measures may be included within display system22, if desired.

As also illustrated inFIG. 3, display system22may provide to the operator of machine10a visual indication of a previous performance of machine10or other similarly-equipped machine. That is, controller20may be configured to recognize, from the operational information collected by data module18, a particular category of machine operation such as, for example, loading, digging, grading, or other suitable operation, and retrieve from the memory of controller20previously recorded machine data associated with a similar, previously performed operation. This recorded information may correspond with optimal control of machine10and be used to recreate an optimal operation for display, comparison, and training purposes on monitor36. For the best possible accuracy, the previously recorded data should correspond with the same machine10operating at the same worksite12, even though information from similar machines and similar worksites may be successfully utilized.

If efficiency measures associated with the comparison operation significantly exceed the same efficiency measures associated with the current operation of machine10, controller20may activate warning lamp42, thereby recommending training to the operator of machine10. That is, if the current operation of machine10significantly deviates from the optimal operation of machine10stored within the memory of controller20, it can be determined that the current operator requires training to improve his/her control of machine10. Upon acceptance of the recommended training, controller20may display upon monitor36the previously performed and recorded optimal operation of machine10back-to-back or simultaneously with the just performed operation of machine10. It is contemplated that the training may be recommended to the operator of machine10in ways other than through the use of warning lamp42such as, for example, through an audible tone or message sounded within operator station38, through a written message appearing on monitor36or other display apparatus within operator station38, or in another similar manner. As the operator views the previously performed machine operation via monitor36before, during, or after his/her self-performed operation, changes to the operator's control technique may be visually discerned by the operator and/or pointed out by controller20during the training simulation.

There may be situations in which immediate training simulation is inconvenient. In these situations, it may be possible for offboard system34to receive from controller20the collected operational data of machine10corresponding to the just performed operation and the previously performed optimal operation, and recreate a simulation environment offboard machine10. The recreated simulation environment may then be displayed on one or more surfaces of offboard system34in 2-D or 3D fashion. In this manner, life-like high-quality training may be carried out without unduly interrupting the operation of machine10.

For example, at an operator's leisure, the two sequences of events (e.g., the self-performed operation and the corresponding optimal operation) may be displayed by offboard system34from a number of operator selectable reference viewpoints. One viewpoint may correspond with a high level view of machine10as it moves about worksite12, and may resemble the image ofFIG. 1. In fact, it is contemplated that actual satellite images may be utilized to simulate machine performance about worksite12, if desired. From this viewpoint, an operator may discern, for example, if an optimal travel route, transmission gear, or travel speed was correctly utilized, or if an approach to a work pile or other cooperating machine was appropriate to maximize efficiency. A second viewpoint may correspond with a close look at work tool movement from inside or outside of operator station38, and may resemble the image ofFIG. 4A. From this viewpoint, an operator may determine, among other things, if work tool placement produced maximum loading, if work tool movement minimized power loss, or if the resultant terrain of worksite12is compatible with a desired terrain or subsequent excavation passes. A third viewpoint may correspond with the inside of operator station38, and may resemble the image ofFIG. 4B. From this viewpoint, an operator may determine if hand movement between actuator devices was timely, or if a sequence of device actuation resulted in the desired excavation contour.

It is contemplated that offboard system34may include an interface resembling that of operator station38. In particular, offboard system34may include the same or similar actuation devices (not shown) such as, for example, steering wheels, joysticks, pedals, and other known devices typically found within operation station38of machine10. Offboard system34may provide a practice simulation environment that incorporates historical machine data and allows operator input for purposes of improving machine control. In this manner, novice operators may be trained without compromising the function or safety of work machine10, other equipment at worksite12, him/herself, or other worksite personnel.

It is further contemplated that offboard system34may include a database (not shown) of historical information indexed by machine type, worksite type, worksite location, environmental conditions (e.g., dry, wet, icy, etc.), time of day, and other such parameters. An operator undergoing training may then select from these parameters particular conditions and therewith compare the difference in machine operation and performance. For example, an operator may select to train with a large wheel loader at a particular quarry during rainy conditions late in the day. The operator may then select to train with a medium wheel loader at the same quarry during dry conditions early in the day, to see how machine operation may differ. From this comparison, an operator may be able to discern techniques applicable to the specific locations, machine, or times of day.

In addition, it is contemplated that multiple user simulation may be provided by offboard system34. In particular, a first user may select for training a wheel loader, while a second user may select a haul truck. The two users may then undergo interactive training to experience how the two machines may optimally cooperate. Fleet manages may use offboard system34in this manner to foster competition among operators or to visualize how well particular machines or operators cooperate at a common worksite. To utilize this function, multiple offboard systems34may be utilized and connected to each other by way of direct communication links, telephone lines, internet connections, or other means known in the art.

INDUSTRIAL APPLICABILITY

The disclosed system may be applicable to any machine where efficient control of the machine is important, and immediate access to the machine is difficult, time consuming, or expensive. In particular, the disclosed system may provide onboard and offboard simulation environments where historical operations of the machine may be recreated for evaluation and training purposes. Operation of simulation system14will be described.

As machine10is operated to perform a task about worksite12, controller20may record signals produced by data module18. For example, as machine10is operated to force work tool24into a surface of worksite12, the various sensing devices18a-eof data module18may track the movements of machine10, the actuation of hydraulic devices30, the articulation of work tool24, the speed of work tool24, the weight or volume of material removed by work tool24, the resulting excavation contour, the operator inputs to various actuation devices within operator station38, the fuel consumption of power source26, and other similar work machine operating parameters. These parameters may be stored within the memory of controller20for later comparison and simulation.

As controller20stores these parameters, it may also compare the stored parameters with previously recorded performance parameters to find a corresponding optimal operation. Continuing with the example from above, according to the specific sequence of operational events, loading information, operator input, etc., controller20may classify the current operation of machine10as a digging operation and search within the memory of controller20for a corresponding optimal digging operation.

Once a corresponding optimal operation has been found, a comparison to the current operation may be made to determine if operator training is required. In other words, if the current operation is being performed at an efficiency level significantly less than the corresponding optimal operation, the current operator may need training specific to the current particular operation. This determination may be made by comparing efficiency measures such as fuel consumption or cycle time between the corresponding operations. If it is determined that training is required, controller20may signal to the operator of machine10the availability of training.

Upon acceptance of the available training, controller20may recreate the just performed operation and the optimal operation for display on monitor36. The two recreated operations may be displayed back-to-back or simultaneously to illustrate to the operator of machine10differences between the operations that can result in improved efficiency. By displaying the two operations with their associated efficiency measures, the operator may discern and/or controller20may point out those operator actions where the most improvement can be achieved. In addition, the difference in magnitude between the efficiency measures may provide motivation for the operator to adjust control techniques.

If immediate simulation of the two operations is inappropriate, the collected data and/or the recreations may be send to offboard system34for display in a separate, more elaborate simulation environment. In this environment, onboard and offboard lifelike views may be displayed in two and/or three dimensions to illustrate machine, work tool, and operator movements. In addition, the operator may be able to interact with the simulation environment via one or more input devices, similar to those found onboard machine10.

Because historical data may be used to recreate and simulate past operations of machine10, the training experienced by the operator may be extensive. In particular, because an operator may view self-performed operations, the operator may directly discern which personal operating techniques need improvement. In addition, because the operator may compare these self-performed operations to optimal operations that were actually performed on the same machine, the goal of improved machine control may seem more attainable to the operator, as compared to theoretical optimal performances. In addition, because the training may be recommended and available immediately, improvement in machine control may likewise be immediate.

It will be apparent to those skilled in the art that various modifications and variations can be made to the method and system of the present disclosure. Other embodiments of the method and system will be apparent to those skilled in the art from consideration of the specification and practice of the method and system disclosed herein. For example, it is contemplated that, as an operator's control of machine10exceeds the recorded optimal performance of machine10, the just performed operation may replace the optimal performance within the memory of controller20for future comparison purposes. It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims and their equivalents.