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

A construction machine typically relies on a number of different sensors to perform tasks in a safe and efficient manner. However, during operation, the harsh vibrations and movements of the construction machine make implementation of those sensors difficult. Conventional sensors are implemented on a construction machine by separately mounting each sensor on the construction machine and running a cable from each sensor to a control unit. Such conventional sensors are tedious to configure and do not allow for the rapid addition or substitution of sensors of different types. For example, <CIT> discloses a sensor device comprising a base module including a battery and including a transceiver configured to communicate with a computing device; and one or more sensor modules configured to releasably couple to the base module, each sensor module configured to receive power from the base module and to provide data to the base module.

The subject-matter for which protection is sought is set out in the appended set of claims <NUM> to <NUM>. In accordance with one or more embodiments, a system for mounting a sensor on a construction machine is described.

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

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

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

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

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

Each construction machine <NUM>-A, <NUM>-B, and <NUM>-C includes a sensor system <NUM>-A, <NUM>-B, and <NUM>-C (collectively referred to as sensor systems <NUM>), respectively. Each sensor system <NUM>-A, <NUM>-B, and <NUM>-C comprises one or more sensors <NUM>-A, <NUM>-B, and <NUM>-C (collectively referred to as sensors <NUM>) and a base <NUM>-A, <NUM>-B, and <NUM>-C (collectively referred to as bases <NUM>), respectively. Sensors <NUM> may include any number of sensors for generating data of, e.g., construction machine <NUM> or construction site <NUM> to facilitate the performance of the construction task. Exemplary sensors of the one or more sensors include a global positioning system (GPS) antenna/sensor, a reflective optical <NUM> degree prim unit for determining a position, a millimeter laser receiver for determining a height (in conjunction with a remote stationary laser), a gyroscope, an accelerometer, a temperature sensor, a moisture sensor, or any suitable sensor or combinations of sensors. Sensors <NUM> are mounted on construction machines <NUM> via bases <NUM>.

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

Communications network <NUM> facilitates communications between construction machines <NUM> (or any other computing device) via control units <NUM> to perform the construction task. Communications network <NUM> may include any suitable network, such as, e.g., a wired or wireless computer network, the Internet, a telephone network, a cellular network, a satellite network, etc. In one embodiment, communications network <NUM> is a mesh network where each construction machine <NUM> acts as a node to cooperate in the distribution of data. In this embodiment, each node is communicatively coupled with all other nodes within communication range.

Construction machines <NUM> operating in construction environment <NUM> generate considerable amounts of vibration and experience other extreme conditions. Advantageously, sensors <NUM> are mounted on construction machines <NUM> via bases <NUM> in a manner to withstand the harsh vibrations and extreme conditions of construction environment <NUM>, while allowing sensors <NUM> to be added, removed, and/or substituted in sensor system <NUM> with minimal reconfiguration of control units <NUM>.

<FIG> shows an illustrative sensor system <NUM> in an interlocked state, in accordance with one or more embodiments. In one embodiment, sensor system <NUM> may be sensor system <NUM> in <FIG>. Sensor system <NUM> includes a top sensor <NUM>-A, an intermediate sensor <NUM>-B, and a bottom sensor <NUM>-C (collectively referred to as sensors <NUM>) coupled to base <NUM> for mounting on a construction machine (e.g., construction machine <NUM> in <FIG>). Sensors <NUM> and base <NUM> are configured to rotatably (or pivotably) interlock with each other to form a sensor system (e.g., sensor system <NUM> of <FIG>). Accordingly, top sensor <NUM>-A is configured to rotatably interlock with intermediate sensor <NUM>-B, intermediate sensor <NUM>-B is configured to rotatably interlock with bottom sensor <NUM>-C, and bottom sensor <NUM>-C is configured to rotatably interlock with base <NUM>.

<FIG> shows an exploded bottom perspective view of sensor system <NUM> in a non-interlocked state and <FIG> shows an exploded top perspective view of sensor system <NUM> in a non-interlocked state, in accordance with one or more embodiments. Intermediate sensor <NUM>-B, bottom sensor <NUM>-C, and base <NUM> each include a top interface <NUM>-A, <NUM>-B, and <NUM>-C (collectively referred to as top interface <NUM>), respectively, as shown in <FIG>. Top sensor <NUM>-A, intermediate sensor <NUM>-B, and bottom sensor <NUM>-C each include a bottom interface <NUM>-A, <NUM>-B, and <NUM>-C (collectively referred to as bottom interface <NUM>), respectively, as shown in <FIG>. Top interface <NUM> is configured to rotatably interlock with bottom interface <NUM> by any suitable means to thereby rotatably interlock, e.g., top sensor <NUM>-A with intermediate sensor <NUM>-B, intermediate sensor <NUM>-B with bottom sensor <NUM>-C, and bottom sensor <NUM>-C with base <NUM>. Base <NUM> is configured to mount sensors <NUM> on a construction machine (not shown). For example, securing element <NUM>, such as, e.g., a pole clamp, may secure base <NUM> to pole <NUM>, which is mounted on the construction machine. Base <NUM> may include a vibration isolator pad <NUM> for absorbing vibrations (e.g., from a construction machine) and reducing the impact of the vibrations on sensors <NUM>.

In one embodiment, one or more sensors <NUM> may include one or more status indicators <NUM>-A and <NUM>-B, such as, e.g., light-emitting diodes (LEDs), display devices, etc. Indicators <NUM>-A and <NUM>-B indicate the status (e.g., power, network connectivity, etc.) of their sensors <NUM>-A and <NUM>-C respectively.

<FIG> shows an exemplary top interface <NUM> and <FIG> shows an exemplary bottom interface <NUM>, in accordance with one embodiment. While interfaces <NUM> and <NUM> are shown and described as being a top interface and a bottom interface respectively, it should be understood that top interface <NUM> may alternatively be a bottom interface (of sensors <NUM>) and bottom interface <NUM> may alternatively be a top interface (sensors <NUM> and/or base <NUM>).

Male coupling elements <NUM> of top interface <NUM> are configured to couple with corresponding female coupling elements <NUM> of bottom interface <NUM> to allow top interface <NUM> to rotatably interlock with bottom interface <NUM>. In one embodiment, male coupling elements <NUM> are radial pins and female coupling elements <NUM> are slotted receptors to form a bayonet mount configuration, as shown and described in more detail with respect to <FIG>. It should be understood that male coupling elements <NUM> and female coupling elements <NUM> may be any suitable coupling element for rotatably interlocking top interface <NUM> and bottom interface <NUM>, and are not limited to the bayonet mount configuration shown and described herein.

<FIG> shows a side view of male coupling elements <NUM> of <FIG>, in accordance with one embodiment. Male coupling element <NUM> is shown as a radial pin having a head <NUM> and a tail <NUM>. Head <NUM> has a diameter larger than the diameter of tail <NUM>.

<FIG> shows a top down view of female coupling elements <NUM> of <FIG>, in accordance with one embodiment. Female coupling element <NUM> is shown as a slotted receptor having receptor <NUM> and slot <NUM>. Receptor <NUM> has a diameter larger than the diameter of head <NUM> of male coupling element <NUM> to allow head <NUM> to be inserted into receptor <NUM>. Slot <NUM> has a width <NUM> larger than the diameter of tail <NUM> but smaller than the diameter of head <NUM> of male coupling element <NUM> to allow top interface <NUM> to rotatably interlock with bottom interface <NUM>.

Referring back to <FIG>, top interface <NUM> includes a protruding center portion <NUM> comprising an extended portion <NUM> and a set of receiving terminals <NUM>. Bottom interface <NUM> includes a recessed center portion <NUM> comprising a notch <NUM> and a set of connecting terminals <NUM>. Each sensor <NUM> and base <NUM> has a plurality of different connections. In one embodiment, the plurality of different connections comprises a connection for power, a connection for ground, a connection for controller area network (CAN) high, a connection for CAN low, a connection for communication between sensors <NUM>, and four connections for other data (e.g., Ethernet connections). Accordingly, each connection has a respective receiving terminal <NUM> and its corresponding connecting terminal <NUM>. The receiving terminals <NUM> of the top interface <NUM> of the base <NUM> communicatively couple to a control unit (e.g., control unit <NUM> of <FIG>) to transmit and/or receive data from sensors <NUM>. While the set of receiving terminals <NUM> and their corresponding connecting terminals <NUM> are shown in <FIG> as having nine connections (i.e., nine receiving terminals <NUM> and nine corresponding connecting terminals <NUM>), it should be understood that the set of receiving terminals <NUM> and their corresponding set of connecting terminals <NUM> may comprise any number of terminals. The terminals in the set of connecting terminals <NUM> may be of any suitable length to allow connecting terminals <NUM> to communicatively couple to corresponding terminals of the set of receiving terminals <NUM> when top interface <NUM> rotatably interlocks with bottom interface <NUM>. In one embodiment, connecting terminals <NUM> are spring loaded connecting terminals <NUM> and receiving terminals <NUM> are flush with a top surface of protruding center portion <NUM> to facilitate rotation of top interface <NUM> with bottom interface <NUM> and thereby communicatively couple connecting terminals <NUM> and receiving terminals <NUM> without damage.

With reference to <FIG>, in operation, to rotatably interlock top interface <NUM> with bottom interface <NUM>, top interface <NUM> is positioned on (i.e., pressed against) bottom interface <NUM> such that head <NUM> of male couplers <NUM> is inserted into receptor <NUM> of female coupling elements <NUM> and protruding center portion <NUM> is inserted into recessed center portion <NUM>. In particular, protruding center portion <NUM> is inserted into recessed center portion <NUM> such that extended portion <NUM> fits within notch <NUM> to thereby ensure top interface <NUM> is correctly oriented with bottom interface <NUM> and receiving terminals <NUM> communicatively couple with their corresponding connecting terminals <NUM>. The insertion of protruding center portion <NUM> into recessed center portion <NUM> causes spring loaded connecting terminals <NUM> to retract to a surface of protruding center portion <NUM>.

Top interface <NUM> is then rotated relative to bottom interface <NUM> such that tail <NUM> is rotated into slot <NUM>. While top interface <NUM> is rotated in the clockwise direction into slot <NUM> in <FIG>, it should be understood that top interface <NUM> may be rotated in the counterclockwise direction into slot <NUM> in a different configuration of female coupling elements <NUM>. The larger diameter of head <NUM> relative to the smaller width <NUM> of slot <NUM> causes top interface <NUM> to rotatably interlock with bottom interface <NUM>. The rotation of top interface <NUM> relative to bottom interface <NUM> causes spring loaded connecting terminals <NUM> to couple with corresponding ones of the receiving terminals <NUM>. The degree and direction of rotation of top interface <NUM> relative to bottom interface <NUM> to rotatably interlock top interface <NUM> with bottom interface <NUM> is based on length <NUM> of slot <NUM>. In one embodiment, the top interface <NUM> is rotated <NUM> degrees clockwise relative to bottom interface <NUM>. Top interface <NUM> includes raised portions <NUM> to create a firm fit with bottom interface <NUM> when interlocked. In one embodiment, slot <NUM> of female coupling elements <NUM> include a vertical spring loaded bullet head plunger (not shown) to securely interlock male coupling elements <NUM> and female coupling elements <NUM> and thereby prevent unintentional unlocking, e.g., due to vibrations.

Advantageously, sensors <NUM> are mounted on construction machines via bases <NUM> in a manner to withstand the harsh vibrations and extreme conditions of a construction environment, while allowing sensors <NUM> to be added, removed, and/or substituted in sensor system <NUM> with minimal reconfiguration of control units <NUM>. In particular, base <NUM> comprises vibration isolator pad <NUM> for reducing the effect of vibrations on sensors <NUM>. Raised portions <NUM> of top interface <NUM> create interference flex pressure with bottom interface <NUM> to further reduce the effects of shock and vibration. Spring loaded connecting terminals <NUM> are able to extend and compress under vibration and shock to main connection.

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

<FIG> shows a flow diagram of a method <NUM> for rotatably interlocking a sensor with a base for mounting the sensor on a construction machine, in accordance with one or more embodiments. Method <NUM> will be described with reference to sensor system <NUM> of <FIG> and <FIG>.

At step <NUM>, a bottom interface <NUM>-C of a sensor <NUM>-C is positioned on a top interface <NUM>-C of a base <NUM>. For example, the sensor <NUM>-C may be a GPS sensor, a gyroscope, an accelerometer, a temperature sensor, a moisture sensor, or any suitable sensor or combinations of sensors. In one embodiment, head <NUM> of male couplers <NUM> of top interface <NUM>-C of base <NUM> is inserted into receptor <NUM> of female coupling elements <NUM> of bottom interface <NUM>-C of sensor <NUM>-C and protruding center portion <NUM> of top interface <NUM>-C of base <NUM> is inserted into recessed center portion <NUM> of bottom interface <NUM>-C of sensor <NUM>-C. In one embodiment, protruding center portion <NUM> of top interface <NUM>-C is inserted into recessed center portion <NUM> of bottom interface <NUM>-C such that extended portion <NUM> of protruding center portion <NUM> fits within notch <NUM> of recessed center portion <NUM>. The extended portion <NUM> and notch <NUM> ensure that sensor <NUM>-C is correctly oriented with base <NUM>, to thereby ensure that connecting terminals <NUM> of bottom interface <NUM>-C of sensor <NUM>-C communicatively couples with their corresponding receiving terminals <NUM> of top interface <NUM>-C of base <NUM>.

At step <NUM>, the bottom interface <NUM>-C of the sensor <NUM>-C is rotated relative to the top interface <NUM>-C of the base <NUM> to rotatably interlock the sensor <NUM>-C with the base <NUM>. In particular, tail <NUM> of coupling element <NUM> of top interface <NUM>-C of the base <NUM> is rotated into slot <NUM> of coupling element <NUM> of bottom interface <NUM>-C of the sensor <NUM>-C. The larger diameter of head <NUM> relative to the smaller width <NUM> of slot <NUM> causes top interface <NUM> to rotatably interlock with bottom interface <NUM>. The rotatably interlocking of the base <NUM> with the sensor <NUM>-C causes one or more terminals <NUM> of the bottom interface <NUM>-C of the sensor <NUM>-C to communicatively couple to corresponding terminals <NUM> of the top interface <NUM>-C of the base <NUM>. The degree and direction of rotation of top interface <NUM>-C relative to bottom interface <NUM>-C to rotatably interlock sensor <NUM>-C with base <NUM> is based on length <NUM> of slot <NUM> and the length of notch <NUM> of recessed portion <NUM> (receiving extended portion <NUM> of protruding center portion <NUM>). In one embodiment, the top interface <NUM>-C is rotated <NUM> degrees clockwise relative to bottom interface <NUM>-C.

In one embodiment, sensor <NUM>-C may include a top interface <NUM>-B, which may be positioned on a bottom interface <NUM>-B of another sensor <NUM>-B. The top interface <NUM>-B of sensor <NUM>-C may be rotated relative to bottom interface <NUM>-B of the other sensor <NUM>-B to rotatably interlock sensors <NUM>-B and <NUM>-C. The rotation of the top interface <NUM>-B of sensor <NUM>-C relative to bottom interface <NUM>-B of the other sensor <NUM>-B causes one or more terminals of the top interface <NUM>-B of sensor <NUM>-C to communicatively couple to corresponding terminals of bottom interface <NUM>-B of the other sensor <NUM>-B.

Claim 1:
A sensor system (<NUM>), comprising:
a sensor (<NUM>) comprising a bottom interface (<NUM>) the bottom interface comprising a recessed center portion (<NUM>) having a notch (<NUM>); and
a base (<NUM>) for mounting the sensor on a construction machine, the base comprising a top interface (<NUM>) for rotatably interlocking with the bottom interface of the sensor, the top interface comprising a protruding center portion (<NUM>) having an extended portion (<NUM>),
the rotatably interlocking of the base with the bottom interface of the sensor causing the extended portion of the protruding center portion of the top interface of the base to rotate within a length of the notch of the recessed center portion of the bottom interface of the sensor, thereby causing one or more terminals (<NUM>) of the bottom interface of the sensor to communicatively couple to corresponding terminals (<NUM>) of the top interface of the base.